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Service

Manual
S/N 525411001 & Above
S/N 525511001 & Above

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6902726 (2-06) Printed in U.S.A. © Bobcat Company 2006
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT CORRECT CORRECT

B-10731a B-19110 B-19109


Never service the Bobcat Compact Use the correct procedure to lift to Cleaning and maintenance are
Track Loader without instructions. lower operator cab. required daily.

WRONG WRONG WRONG

B-19108 B-19111 B-19107


Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
paintee parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an approved attachments not approved by
Avoid exhaust fume leaks which lift arm support device. Replace it Bobcat Company.
can kill without warning. Exhaust if damaged.
system must be tightly sealed.

WRONG WRONG WRONG

B-19106 B-19105 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, electrical flammable and explosive gases.
checking fluids. contact, hot parts and exhaust. Keep arcs, sparks, flames and
Never service or adjust loader Wear eye protection to guard from lighted tobacco away from
with the engine running unless battery acid, compressed springs, batteries.
instructed to do so in the manual. fluids under pressure and flying Batteries contain acid which
Avoid contact with leaking debris when engines are running burns eyes or skin on contact.
hydraulic fluid or diesel fuel or tools are used. Use eye Wear protective clothing. If acid
under pressure. It can penetrate protection approved for type of contacts body, flush well with
the skin or eyes. welding. water. For eye contact flush well
Never fill fuel tank with engine Keep rear door closed except for and get immediate medical
running, while smoking or when service. Close and latch door attention.
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW24-0805
ALPHABETICAL INDEX

ADVANCED CONTROL SYSTEM (ACS) ............... 60-01 ENGINE SPECIFICATIONS ...........................SPEC-01


AIR CLEANER .................................................... 70-01 ENGINE SPEED CONTROL ...................................70-01
AIR CLEANER SERVICE ....................................... 10-01 ENGINE SPEED CONTROL (SELECTABLE
AIR CONDITIONING SERVICE.............................. 80-01 JOYSTICK CONTROL) (SJC) ...............................70-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 EVAPORATOR ........................................................80-01
ALTERNATOR ........................................................ 60-01 EVAPORATOR/HEATER UNIT................................80-01
EXPANSION VALVE ................................................80-01
BASIC TROUBLESHOOTING ................................ 80-01
BATTERY............................................................ 60-01 FAN GEARBOX .......................................................10-01
BOBCAT CONTROLLER ........................................ 60-01 FLYWHEEL AND HOUSING .................................70-01
BICS™ SYSTEM ............................................... 60-01 FLYWHEEL RPM SENSOR ....................................60-01
BLOWER FAN ........................................................ 80-01 FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01
BOB-TACH................................................... 10-01, 50-01 FUEL SYSTEM........................................................10-01
BRAKE .................................................................... 40-01 FUEL TANK .............................................................50-01
BUCKET POSITION VALVE ................................20-01
GENERAL AIR CONDITIONING SERVICE
GUIDELINES .........................................................80-01
CALIBRATION
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 60-01
HEATER COIL .........................................................80-01
CHARGE PRESSURE ............................................ 30-01
HEATER VALVE ......................................................80-01
COMPONENTS ...................................................... 80-01 HYDRAULIC CONNECTION SPECIFICATIONS .. SPEC-01
COMPRESSOR ...................................................... 80-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
CONDENSER ......................................................... 80-01 (ADVANCED CONTROL SYSTEM) (ACS) ..........20-01
CONTROL HANDLE ............................................... 50-01 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
CONTROL HANDLE (ADVANCED CONTROL (ADVANCED CONTROL SYSTEM) (ACS) ..........20-01
SYSTEM) (ACS) SELECTABLE HAND/FOOT HYDRAULIC CONTROL VALVE (FOOT CONTROL) .20-01
CONTROL ............................................................ 50-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
CONTROL HANDLE (SELECTABLE JOYSTICK (FOOT CONTROL)...............................................20-01
CONTROL) (SJC) ................................................. 50-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
CONTROL PANEL (ADJUSTABLE PINTLES)........ 50-01 (SELECTABLE JOYSTICK CONTROL) (SJC) ......20-01
CONTROL PANEL HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(NON-ADJUSTABLE PINTLES)............................ 50-01 (SELECTABLE JOYSTICK CONTROL) (SJC) ......20-01
CONTROL PANEL (SELECTABLE JOYSTICK HYDRAULIC FILTER HOUSING .............................20-01
CONTROL) (SJC) ................................................. 50-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
CONTROL PEDALS ............................................... 50-01 HYDRAULIC FLUID SPECIFICATIONS ........ SPEC-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
CONTROLLER (SELECTABLE JOYSTICK HYDRAULIC PUMP ................................................20-01
CONTROL) (SJC) ................................................. 60-01 HYDRAULIC PUMP (CHARGE)..............................20-01
CONVERSIONS ............................................ SPEC-01 HYDRAULIC PUMP (HI FLOW) ..............................20-01
COOLING FAN ....................................................... 70-01 HYDRAULIC PUMP (SELECTABLE JOYSTICK
CYLINDER (LIFT) ................................................... 20-01 CONTROL) (SJC)..................................................20-01
CYLINDER (POWER BOB-TACH).......................... 20-01 HYDRAULIC PUMP (HI FLOW) (SELECTABLE
CYLINDER (TILT) ............................................... 20-01 JOYSTICK CONTROL) (SJC) ...............................20-01
HYDRAULIC/HYDROSTATIC FILTER ....................20-01
DIAGNOSTICS SERVICE CODES ..................... 60-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
DRIVE BELT ........................................................... 30-01 HYDROSTATIC MOTOR ..................................... 30-01
DRIVE COMPONENTS .......................................... 40-01 HYDROSTATIC MOTOR (SELECTABLE JOYSTICK
CONTROL) (SJC)..................................................30-01
HYDROSTATIC PUMP ........................................ 30-01
ELECTRICAL/HYDRAULIC CONTROLS
HYDROSTATIC PUMP (SELECTABLE JOYSTICK
REFERENCE ........................................................ 60-01
CONTROL) (SJC)..................................................30-01
ELECTRICAL/HYDRAULIC CONTROLS
HYDROSTATIC SYSTEM INFORMATION ..........30-01
REFERENCE (SELECTABLE JOYSTICK
CONTROL) (SJC) ................................................. 60-01 INSTRUMENT PANEL.............................................60-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 INSIDE ACCESS PANEL ........................................50-01
ENGINE ................................................................. 70-01 INSIDE ACCESS PANEL (SELECTABLE JOYSTICK
ENGINE COOLING SYSTEM ................................. 10-01 CONTROL) (SJC)..................................................50-01
ENGINE LUBRICATION SYSTEM.......................... 10-01
ALPHABETICAL INDEX (CONT’D)

LIFT ARM ................................................................50-01


LIFT ARM BY-PASS CONTROL VALVE .............20-01
LIFT ARM SUPPORT DEVICE ............................10-01
LIFTING AND BLOCKING THE LOADER...............10-01
LIGHTS ............................................................... 60-01
LOADER SPECIFICATIONS ............................. SPEC-01
LUBRICATING THE LOADER .................................10-01

MAIN RELIEF VALVE ..............................................20-01


MUFFLER................................................................70-01

OIL COOLER (SEAL TO CONNECTION) (STC) ....30-01


OPERATOR CAB......................................10-01, 50-01
OPERATOR SEAT...................................................50-01

POWER BOB-TACH ................................ 10-01, 50-01


POWER BOB-TACH BLOCK...................................20-01
PRESSURE RELIEF VALVE ...................................80-01
PRESSURE SWITCH..............................................80-01

RADIATOR.............................................................. 70-01
REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ...................................................... 50-01
REAR GRILL ....................................................... 50-01
RECEIVER/DRIER ..................................................80-01
RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ................................80-01
REMOTE START ................................................ 10-01

SAFETY...................................................................80-01
SEAT BAR ...............................................................50-01
SEAT BAR SENSOR ...............................................60-01
SERVICE PC (LAPTOP COMPUTER) ....................60-01
SERVICE SCHEDULE ............................................10-01
SPEED SENSOR (SELECTABLE JOYSTICK
CONTROL) (SJC)..................................................60-01
STARTER ................................................................60-01
SYSTEM CHARGING AND RECLAMATION ..........80-01
SYSTEM TROUBLESHOOTING CHART ...............80-01

TEMPERATURE/PRESSURE .................................80-01
THERMOSTAT.........................................................80-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE BOBCAT LOADER.............10-01
TROUBLESHOOTING.............................................70-01

ACS- ADVANCED CONTROL SYSTEM


AHC- ADVANCED HAND CONTROL SYSTEM
BICS™-BOBCAT INTERLOCK CONTROL SYSTEM
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC


SYSTEM
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X HYDROSTATIC


SYSTEM
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE


SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01


MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL


SYSTEM &
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01 SERVICE

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

HVAC

SPECIFICATIONS

SPECIFICATIONS

T300 Bobcat Loader


I Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.

A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.

2. Check that ROPS mounting 10. Enclosure door latches must


hardware is tightened and is open and close freely.
Bobcat approved.

3. The seat belt must be 11. Bob-Tach wedges and


correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.

4. The seat bar must be 12. Safety treads must be in good


correctly adjusted, clean and condition.
lubricated.

5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).

6. Machine signs must be 14. Check hydraulic fluid level,


legible and in the correct engine oil level and fuel
location. supply.

7. Steering levers and foot 15. Inspect for fuel, oil or


pedals must return to neutral. hydraulic fluid leaks.

8. Check for correct function of 16. Lubricate the loader.


the work lights

T300 Bobcat Loader


II Service Manual
17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.

18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.

19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tracks for wear and 25. Recommend to the owner
tension. that all necessary corrections
be made before the machine
is returned to service.

21. Inspect for loose or broken


parts or connections.

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.

T300 Bobcat Loader


III Service Manual
T300 Bobcat Loader
IV Service Manual
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.

• The Skid-Steer Loader Operator Training Course is


available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Skid-Steer Loader. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.

• The Skid-Steer Loader Safety Video is available from


your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.

SI SSL-0206 SM

T300 Bobcat Loader


V Service Manual
SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner/operator review the recommended


uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.

Call Before You Dig


1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)

SI SSL-0206 SM

T300 Bobcat Loader


VI Service Manual
SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.

The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.

Flammable debris (leaves, straw, etc.) must be removed


regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.

The spark arrestor muffler is designed to control the


emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.

• Do not use the machine where exhaust, arcs, sparks


or hot components can contact flammable material,
explosive dust or gases.

• The operator cab, engine compartment, and engine


• Know where fire extinguishers and first aid kits are
cooling system must be inspected every day and
located and how to use them. Fire extinguishers are
cleaned if necessary to prevent fire hazard and
available from your Bobcat dealer [Figure 1].
overheating.

• Check all electrical wiring and connections for


damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for


damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.

• Do not use ether or starting fluids on any engine


which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.

• Always clean the machine, disconnect the battery,


and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.

• Stop the engine and let it cool before adding fuel. NO


SMOKING!
SI SSL-0206 SM

T300 Bobcat Loader


VII Service Manual
T300 Bobcat Loader
VIII Service Manual
SERIAL NUMBER LOCATION Engine Serial Number

Always use the serial number of the loader when Figure 3


requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.

Loader Serial Number

Figure 2

P-48339

The engine serial number is located on the engine block


[Figure 3].

P-31226

The loader serial number plate is located on the outside


of the loader frame [Figure 2].

Explanation of loader Serial Number:

XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)

1. The four digit Model/Engine Combination Module


number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies


the order which the loader is produced.

T300 Bobcat Loader


IX Service Manual
DELIVERY REPORT

Figure 4

B-16315

The Delivery Report must be filled out by the dealer and


signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
4].

T300 Bobcat Loader


X Service Manual
LOADER IDENTIFICATION

FRONT
LIGHTS * REAR AUXILIARY
QUICK COUPLERS
GRAB
HANDLES

OPERATOR SEAT
with SEAT BELT
& SEAT BAR

TILT
CYLINDERS

FRONT AUXILIARY
QUICK COPULERS

†BUCKET
STEPS
BUCKET
STEPS

LIFT LIFT ARM


CYLINDER SUPPORT DEVICE

REAR
GRILL
LIFT ARM

REAR
LIGHT
TAIL
REAR LIGHT
DOOR TRACKS B-16951a
B-16950

* Option or Field Accessory


† Many buckets and other attachments are available.

T300 Bobcat Loader


XI Service Manual
T300 Bobcat Loader
XII Service Manual
SAFETY AND MAINTENANCE

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1


Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-140-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1


Adding The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-4
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
Cleaning Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
DRIVE
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1 SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1


Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
ELECTRICAL
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SYSTEM &
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ANALYSIS
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2 ENGINE
SERVICE
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . 10-120-2 SPECIFICATIONS
Replacing Hydraulic Fluid And Case Drain Filters . . . . . . 10-120-3

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1


Installing The Lift Arm Support Device. . . . . . . . . . . . . . . . 10-20-1
Removing The Lift Arm Support Device. . . . . . . . . . . . . . . 10-20-2

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-150-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Continued On Next Page

T300 Bobcat Loader


10-01 Service Manual
SAFETY AND MAINTENANCE (CONT’D)

POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1


Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60-3
Procedure For Loader With Attachments Control Harness . . . . . .10-60-2
Procedure For Loader W/O Attachments Control Harness . . . . . .10-60-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-70-1


Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-70-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-50-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-50-1

TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . .10-40-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE


STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01)
UNLESS OTHERWISE SPECIFIED.

T300 Bobcat Loader


10-02 Service Manual
LIFTING AND BLOCKING THE LOADER Figure 10-10-2

Procedure

Figure 10-10-1

P-37658

Lift the rear of the loader and install jackstands [Figure


B-7023A 10-10-2].

Figure 10-10-3

WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0903
P-37659

Read the Removal & Installation, Disassembly &


Assembly, etc. completely to become familiar with the Lift the front of the loader and put jackstands under the
procedure before beginning [Figure 10-10-1]. axle tubes [Figure 10-10-3].

Always park the loader on a level surface. NOTE: Make sure the jackstands do not touch the
tracks.

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

T300 Bobcat Loader


10-10-1 Service Manual
T300 Bobcat Loader
10-10-2 Service Manual
LIFT ARM SUPPORT DEVICE Remove the lift arm support device (Item 1) [Figure 10-
20-1] from the storage position.
Installing The Lift Arm Support Device
The operator must stay in the operator seat with the seat
Figure 10-20-1 belt fastened and the seat bar lowered, until the lift arm
support device is installed.

Start the engine and raise the lift arms all the way up.

Figure 10-20-2

P-10136
1

P-37658 P-31244

WARNING P-31264

Never work on a machine with the lift arms up unless


Have a second person install the lift arm support device
the lift arms are secured by an approved lift arm
over the rod of one of the lift cylinders [Figure 10-20-2].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
The lift arm support device must be tight against the
to fall and cause injury or death.
W-2059-0598
cylinder rod. The tabs of the lift arm support device must
be under the cylinder as shown (Inset) [Figure 10-20-2].

WARNING
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2271-1197

Put jackstands under the rear corners of the loader frame


(Inset) [Figure 10-20-1].

T300 Bobcat Loader


10-20-1 Service Manual
LIFT ARM SUPPORT DEVICE (CONT’D)

Installing The Lift Arm Support Device (Cont’d)

Figure 10-20-3

P-31265

Lower the lift arms slowly until the lift arm support device
is held between the lift arms and lift cylinder [Figure 10-
20-3].

Removing The Lift Arm Support Device

The operator must be in the operator's seat, with the seat


belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
all the way.

Start the engine, raise the lift arms all the way up.

Have a second person remove the lift arm support


device.

Lower the lift arms all the way and stop the engine.

Return the lift arm support device to storage position and


secure with clamping knobs.

Remove the jackstands.

T300 Bobcat Loader


10-20-2 Service Manual
OPERATOR CAB Figure 10-30-2

Description

The Bobcat loader has an operator cab (ROPS and


FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for roll over protection.

ROPS/FOPS - Roll Over Protective Structure per SAE


J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level I. Level II
is available.

Level I - Protection from falling bricks, small concrete P-31288 P-31289


blocks, and hand tools encountered in operations such
as highway maintenance, landscaping, and other
construction site services. Loosen the nut (both sides) at the front corner of the
operator cab [Figure 10-30-2].
Level II - Protection from falling trees, rocks; for
machines involved in site clearing, overhead demolition Remove the nuts and plates [Figure 10-30-2] (both
or forestry. sides).

Raising The Operator Cab Figure 10-30-3

Figure 10-30-1

P-31267

P-37658
Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
Always stop the engine before raising or lowering the mechanism engages [Figure 10-30-3].
cab.

Stop the loader on a level surface. Lower the lift arms. If


the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing The Lift
Arm Support Device on Page 10-20-1.)

Install jackstands under the rear of the loader frame


[Figure 10-30-1].

T300 Bobcat Loader


10-30-1 Service Manual
OPERATOR CAB (CONT'D) Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-30-4].
Raising The Operator Cab (Cont’d)
Release the latching mechanism (Inset) [Figure 10-30-4]
Advanced Hand Control Only and pull the cab all the way down.

Figure 10-30-5

P-31288 P-31289

WARNING Install the plates and nuts [Figure 10-30-5] (both sides).

Tighten the nuts to 40-50 ft.-lb. (54-68 N•m) torque.


Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
Emergency Exit
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
Figure 10-30-6
and falling objects, and result in injury or death.
W-2069-1299

Lowering The Operator Cab


Figure 10-30-4

N-19386

The front opening on the operator cab and rear window


provide exits.

N-20120 P-31268
REAR WINDOW (If Equipped)

Always stop the engine before raising or lowering the Pull on the tag on the top of the rear window to remove
cab. the rubber cord [Figure 10-30-6].

NOTE: Make sure the seat bar is fully raised or


lowered when lowering the cab. Always use
the grab handles to lower the cab.

T300 Bobcat Loader


10-30-2 Service Manual
OPERATOR CAB (CONT'D) Figure 10-30-9

Emergency Exit (Cont’d)

Figure 10-30-7

P-28359

Push the window out with your foot [Figure 10-30-9] at


P-31269 any corner of the window.

Exit through the front door.


Push the rear window out of the rear of the operator cab.

Exit through the rear of the operator cab [Figure 10-30-


7].

Figure 10-30-8

N-20171

FRONT DOOR (If Equipped)

NOTE: When an Operator Cab Enclosure Kit is


installed, the window of the front door can be
used as an emergency exit [Figure 10-30-8].

NOTE: When the special applications kit is installed,


the front door cannot be used for an
emergency exit.

Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].

T300 Bobcat Loader


10-30-3 Service Manual
T300 Bobcat Loader
10-30-4 Service Manual
TRANSPORTING THE BOBCAT LOADER Figure 10-40-2

Procedure

Figure 10-40-1

P-31228A P-31230A

P-37436

WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. 6595014 P-31916
W-2058-0494

Use the following procedure to fasten the Bobcat loader


A loader with an empty bucket or no attachment must be to the transport vehicle to prevent the loader from moving
loaded backward onto the transport vehicle [Figure 10- during sudden stops or when going up or down slopes
40-1]. [Figure 10-40-2].
Be sure the transport and towing vehicles are of • Lower the bucket or attachment to the floor.
adequate size and capacity (See Capacities on Page
SPEC-10-4.). • Stop the engine.
The rear of the trailer must be blocked or supported • Engage the parking brake.
[Figure 10-40-1] when loading or unloading the loader to
prevent the front end of the trailer from raising up. • Install chains at the front and rear loader tie down
positions (Inset) [Figure 10-40-2].

• Fasten each end of the chain to the transport vehicle.

T300 Bobcat Loader


10-40-1 Service Manual
T300 Bobcat Loader
10-40-2 Service Manual
TOWING THE LOADER

Procedure

Because of the design of the loader, there is not a


recommended towing procedure.

• The loader can be lifted onto a transport vehicle.

• The loader can be skidded a short distance to move


for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires/tracks will not turn.) There might be slight
wear to the tires/tracks when the loader is skidded.

The towing chain (or cable) must be rated at 1 & 1/2


times the weight of the loader. (See LOADER
SPECIFICATIONS (T300) on Page SPEC-10-1.)

T300 Bobcat Loader


10-50-1 Service Manual
T300 Bobcat Loader
10-50-2 Service Manual
REMOTE START Figure 10-60-2

Procedure For Loader W/O Attachments Control


Harness

Figure 10-60-1

1
1

P-28365

Remove the cap (Item 1) [Figure 10-60-2] from the


loader harness.
P13841
When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-60-2].
The tool listed will be need to do the following procedure:
Figure 10-60-3
MEL1563 - Remote Start Tool Kit

The remote start (Item 1) [Figure 10-60-1] is required


when the operator cab is in the raised position for service
and the service technician needs to turn the key switch
on or start the engine. Example: adjusting the steering 2
linkage.

Lift and block the loader. (See Procedure on Page 10-10-


1.) 1

Raise the lift arms (if required by the procedure) and


install an approved lift arm support device. (See Installing
The Lift Arm Support Device on Page 10-20-1.)
P-28366
Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Connect the remote start tool to the engine harness
Open the rear door of the loader. connector (Item 1) [Figure 10-60-3].

The connector (Item 2) [Figure 10-60-3] from the remote


start harness is not used in the remote start procedure
and should remain capped.

NOTE: The key switch on the right-hand side


operator panel must be in the off position or
the Remote Start Kit will not operate.

T300 Bobcat Loader


10-60-1 Service Manual
REMOTE START (CONT'D) Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Procedure For Loader W/O Attachments Control
Harness (Cont’d) Open the rear door of the loader.

Figure 10-60-5

WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working in the engine area 1
it is important to remove the operator panel keys.
W-2357-0899

P-28362
Procedure For Loader With Attachments Control
Harness
Figure 10-60-6
Figure 10-60-4

P-28364
P13841

Disconnect the attachment control harness (Item 1)


The tool listed will be need to do the following procedure: [Figure 10-60-5] & [Figure 10-60-6] from the loader
harness (Item 2) [Figure 10-60-6].
MEL1563 - Remote Start Tool Kit

The remote start (Item 1) [Figure 10-60-4] is required


when the operator cab is in the raised position for service
and the service technician needs to turn the key switch
on or start the engine. Example: adjusting the steering
linkage.

Lift and block the loader. (See Procedure on Page 10-10-


1.)

Raise the lift arms (if required by the procedure) and


install an approved lift arm support device. (See Installing
The Lift Arm Support Device on Page 10-20-1.)

T300 Bobcat Loader


10-60-2 Service Manual
REMOTE START (CONT'D) Procedure

Procedure for Loader With Attachments Control Figure 10-60-8


Harness (Cont’d)

Figure 10-60-7
1

3 2

P13842
1

P-28363 The remote start tool (Item 1) [Figure 10-60-8] has three
rocker switches.

Connect the remote start tool (Item 1) [Figure 10-60-7] to Figure 10-60-9
the loader harness connector (Item 2) [Figure 10-60-6].

The connector (Item 3) [Figure 10-60-7] on the remote


start harness is not used in the remote start procedure
and should remain capped.
2
NOTE: The key switch on the right-hand side 1
3
operator panel must be in the off position or
the Remote Start Kit will not operate.

WARNING
N-19541
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the The traction lock switch (Item 1) [Figure 10-60-9] is used
loader can still be started from the operator panel to turn traction lock on or off. Push the switch to the
inside the cab. Placing the key switch of the remote override position. The switch will illuminate to indicate
start tool in the run position disconnects the traction lock OVERRIDE, in this position the wheels are
operator panel key switch from the start circuit. If the able to turn.
service technician will be working in the engine area The maximum flow/variable flow switch (Item 2) [Figure
it is important to remove the operator panel keys. 10-60-9] is used to activate the auxiliary hydraulics.
W-2357-0899 Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-60-9]
is used to release hydraulic pressure to the rear auxiliary
couplers, and right hand auxiliary. (If so equipped.) To
release pressure; push and hold the switch for three
seconds.

T300 Bobcat Loader


10-60-3 Service Manual
REMOTE START (CONT'D)

Procedure (Cont’d)

NOTE: With the engine running; pushing and holding


the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to press the switch
after the engine has stopped.

T300 Bobcat Loader


10-60-4 Service Manual
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and signs
(decals) on machine. Follow warnings and instructions in the manuals when
WARNING making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0903

SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED ■ ■ ■


8-10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed.Do not overfill.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and
damaged components.
Engine Cooling System Clean debris from oil cooler, radiator & grill. Check coolant level COLD and add
premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the sear bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check that four (4) BICS™ indicator lights and functions are activated. See
(BICS™) details in this Manual.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater and A/C Filters Clean or replace filters as needed during heating/cooling season.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Foot Pedals or Hand Controls, Check for correct operation. Repair or adjust as needed.
and Steering Levers
Parking Brake Check operation.
Tracks Check for damaged tracks and correct tension. Adjust as needed.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Shaft Grease fittings.
Engine/Hydro. Drive Belt Check for wear or damage. Check idler arm stop. *
Alternator Belt Check tension and adjust as needed.
Air Conditioner Belt Check belt for wear. Adjust or replace as needed.
Bobcat Interlock Control System Check the function of the lift arm by-pass control.
(BICS™)
Fuel Filter Replace filter element.
Fan Drive Gearbox Check gear lube level.
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd./Hydro. Filter ● Replace the filter element.
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter. ^ ❍
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters.
Engine Valves Adjust the engine valves. #
Hydrostatic Motor Carrier Replace Oil with High Performance Synthetic Oil P/N 6682546
* Inspect the new or replacement belt after first 50 hours of operation.
● Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 500 hours thereafter.
❍ When operating under severe conditions, change oil and filter every 250 hours.
# After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter.
■ Or every 12 months.

T300 Bobcat Loader


10-70-1 Service Manual
T300 Bobcat Loader
10-70-2 Service Manual
AIR CLEANER SERVICE If the filter element needs replacement, the CODE [01-
17] (Air Filter Plugged) will show in the HOURMETER /
Replacing Filter Element CODE DISPLAY (Item 2) [Figure 10-80-2].

Figure 10-80-1 Figure 10-80-3

B-16300

P-48340

B-15552
B-15553
OUTER FILTER

It is important to change the air filter element only when Disengage the wing nut (Item 1) [Figure 10-80-3] and
the Air Cleaner Icon in the right panel is ON (Item 1) remove the dust cover.
[Figure 10-80-1] and you hear three beeps from the
alarm. Figure 10-80-4

Replace the inner filter every third time the outer filter is
replaced or as indicated on See Replacing Filter Element
(Cont'd) on Page 10-80-2.

Figure 10-80-2 1

P-48341

1
Remove the wing nut (Item 1) [Figure 10-80-4] and
remove the outer filter element.

NOTE: Make sure all sealing surfaces are free of dirt


and debris.

B-15551 Install a new outer element, and install the wing nut.

Install the dust cover and install the outer wing nut.
Press and hold the LIGHT Button (Item 1) [Figure 10-80-
2] for two seconds. Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.

T300 Bobcat Loader


10-80-1 Service Manual
AIR CLEANER SERVICE (CONT'D) Figure 10-80-6

Replacing Filter Element (Cont'd)

Figure 10-80-5

1
1

P-48340

Install the new inner element.


P-48342
Install the dust cover and wing nut (Item 1) [Figure 10-
80-6].
INNER FILTER

Only replace the inner filter element under the following


conditions:

• Replace the inner filter element every third time the


outer filter is replaced.

• After the outer element has been replaced, start the


engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.

Remove the inner filter element (Item 1) [Figure 10-80-


5].

NOTE: Make sure all sealing surfaces are free of dirt


and debris.

T300 Bobcat Loader


10-80-2 Service Manual
ENGINE COOLING SYSTEM Figure 10-90-2

Cleaning Cooling System

Figure 10-90-1

P-34868

Lift the overflow tank (Item 1) [Figure 10-90-2] out of its


P-34869 mount bracket.

Remove the cotter pin (Item 2) [Figure 10-90-2] (both


Check the cooling system every day to prevent over- sides) from the oil cooler.
heating, loss of performance or engine damage.
Figure 10-90-3

WARNING
Wear safety glasses to prevent eye injury when any
of the flollowing conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285

Remove the rear grill. (See Removal And Installation on


Page 50-60-1.) P-34867

Use air pressure or water pressure to clean the top of the


oil cooler [Figure 10-90-1]. Raise the oil cooler [Figure 10-90-3].

Use air pressure or water pressure to clean the top of the


engine oil cooler.

T300 Bobcat Loader


10-90-1 Service Manual
ENGINE COOLING SYSTEM (CONT’D)

Cleaning Cooling System (Cont’d)

Figure 10-90-4

Access
Cover

P-31691

NOTE: The access cover (both sides) must be in


place to ensure proper air flow through the oil
cooler which will ensure correct cooling for
the engine/hydraulic system [Figure 10-90-4].

T300 Bobcat Loader


10-90-2 Service Manual
ENGINE COOLING SYSTEM (CONT’D)

Checking The Coolant Level


IMPORTANT
Figure 10-90-5
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
MAX
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
MIN
MAX
damage.
P-45106
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength


concentrated coolant can cause serious premature
engine damage.
P-62252 I-2124-0497

Open the rear door and raise the rear grill.

Check the coolant level [Figure 10-90-5]. The level


marks are on the outside of the tank. Coolant level must
be between the MIN and MAX marks on the coolant
recovery tank when the engine is cold.

Close the rear door before operating the loader.

T300 Bobcat Loader


10-90-3 Service Manual
ENGINE COOLING SYSTEM (CONT’D) Add premixed coolant, 47% water and 53% propylene
glycol to the recovery tank if the coolant level is low.
Adding The Coolant
One gallon and one pint (4,3 L) of propylene glycol mixed
with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34°F (-37°C) freeze protection.
WARNING Use a refractometer to check the condition of propylene
glycol in your cooling system.
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
Fill the tank with the premixed coolant until it is between
the MIN and MAX marks. Install the coolant tank cap.

Figure 10-90-6 Run the engine until it is at operating temperature. Stop


the engine. Check the coolant level in the coolant tank
when cool. Add coolant as needed.

Install the rear grill and close the rear door.

IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system


P-62252 efficiency and may cause serious premature engine
damage.

Open the rear door and remove the rear grill. Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
Remove the coolant tank cap (Item 1) [Figure 10-90-6]. boiling point and freeze protection of the system.

Mix the coolant in a separate container. (See Capacities Always add a premixed solution. Adding full strength
on Page SPEC-10-4.) concentrated coolant can cause serious premature
engine damage.
NOTE: The loader is factory filled with propylene I-2124-0497
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.

T300 Bobcat Loader


10-90-4 Service Manual
FUEL SYSTEM Figure 10-100-2

Fuel Specifications WRONG

Use only clean, high quality diesel fuel, Grade No. 2 or


Grade No. 1.

The following is one suggested blending guideline which


should prevent fuel gelling problems:

Temp. F° (C°) No. 2 No. 1


+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
B-15986
We recommend an operator contact their fuel supplier for
local recommendations.
Use a clean, approved safety container to add fuel of the
Filling The Fuel Tank correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].

WARNING Install and tighten the fuel fill cap [Figure 10-100-1].

Stop and cool the engine before adding fuel. NO


SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887

Figure 10-100-1

P-31254

Remove the fuel fill cap (Item 1) [Figure 10-100-1].

T300 Bobcat Loader


10-100-1 Service Manual
FUEL SYSTEM (CONT'D) Removing Air From The Fuel System

Fuel Filter Figure 10-100-4

Figure 10-100-3

2 1

1
P-48343

P-48343
After replacing the fuel filter element or when the fuel
tank has run out of fuel, the air must be removed from the
(See SERVICE SCHEDULE on Page 10-70-1.), for the fuel system prior to starting the engine.
recommended service interval when to remove the water
from the fuel filter. Loosen the air vent plug (Item 1) [Figure 10-100-4] at the
top of the fuel filter.
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter element to drain any water from the Figure 10-100-5
filter.

(See SERVICE SCHEDULE on Page 10-70-1.), for the


recommended service interval when to replace the fuel
filter.

To replace the fuel filter element, use a filter wrench to


remove the filter element (Item 2) [Figure 10-100-3].

Clean the area around the filter housing. Put oil on the 1
seal of the new filter element. Install the fuel filter, and
hand tighten. Remove the air from the fuel system.

P-48344

Operate the hand pump (priming bulb) (Item 1) [Figure


10-100-5] until the fuel flows from the air vent plug with
out air bubbles.

Tighten the air vent plug.

T300 Bobcat Loader


10-100-2 Service Manual
ENGINE LUBRICATION SYSTEM Replacing Oil And Filter

Checking Engine Oil Figure 10-110-2

Figure 10-110-1

P-48345

P-48345
(See SERVICE SCHEDULE on Page 10-70-1.), for the
service interval for replacing the engine oil and filter.
Check the engine oil level every day.
Run the engine until it is at operating temperature. Stop
Before starting the engine for the work shift, open the the engine.
rear door. Remove the dipstick (Item 1) [Figure 10-110-
1]. Open the rear door. Remove the drain hose (Item 1)
[Figure 10-110-2] from its storage position. Remove the
Keep the oil level between the marks on the dipstick. cap and drain the oil into container.

Use a good quality motor oil that meets API Service


Classification of CD, CE or better. (See Oil Chart below.)

Oil Chart

T300 Bobcat Loader


10-110-1 Service Manual
ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-4

Replacing Oil And Filter (Cont’d)

Figure 10-110-3

P-48347

Remove the filler cap (Item 1) [Figure 10-110-4].


P-48345
Put 12 qts. (11 L) of oil in the engine.

Start the engine and let it run for several minutes. Stop
the engine. Check for leaks and check the oil level. Add
WARNING oil as needed if it is not at the top mark on the dipstick.

Always clean up spilled fuel or oil. Keep heat, flames,


sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285

Remove the oil filter (Item 1) [Figure 10-110-3].

Clean the filter housing surface. Put clean oil on the new
oil filter gasket. Install the filter and hand tighten only.

Install and tighten the drain cap on the drain hose.

T300 Bobcat Loader


10-110-2 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-2

Checking And Adding Fluid

Figure 10-120-1

Sight
Gauge
1

P-4613

P-31692

If fluid is needed, remove the fill cap (Item 1) [Figure 10-


P-31692 120-2].

Add the fluid as needed to bring the level to the center of


Use only recommended fluid in the hydraulic system. the sight gauge.
(See LOADER SPECIFICATIONS (T300) on Page
SPEC-10-1.) Figure 10-120-3

Hydraulic Fluid Chart

P-30011

NOTE: Before installing the fill cap, make sure the


rubber gasket (Item 1) [Figure 10-120-3] is
installed on the fill cap.
To check the reservoir, use the following procedure:

Put the Bobcat loader on a level surface. Lower the lift


arms and tilt the Bob-Tach fully back. Stop the engine.

Check the fluid level at the sight gauge [Figure 10-120-


1]. The fluid level must show in the sight gauge.

T300 Bobcat Loader


10-120-1 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D)

Hydraulic/Hydrostatic Filter Replacement

Figure 10-120-4

P-34904

(See SERVICE SCHEDULE on Page 10-70-1.), for the


correct service interval.

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Use a filter wrench to remove the filter element (Item 1)


[Figure 10-120-4].

Clean the surface of the filter housing where the element


seal contacts the housing. Put clean oil on the rubber
seal of the filter elements.

Install and hand tighten the filter elements.

T300 Bobcat Loader


10-120-2 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Pull the reservoir drain hose (Item 1) [Figure 10-120-5]
out the motor cover hole. Remove the plug and drain the
Replacing Hydraulic Fluid And Case Drain Filters fluid into a container.

Figure 10-120-5 Figure 10-120-6

P-31286 P-34905

(See SERVICE SCHEDULE on Page 10-70-1.), for the Disconnect the hoses from the hydrostatic motor case
service interval. drain filter (Item 1) [Figure 10-120-6].

Replace the fluid if it becomes contaminated or after Remove the case drain filter and clean thoroughly with
major repair. clean solvent.

Also clean the hydrostatic motor case drain filter Install the case drain filter and tighten the hoses.
thoroughly after a major repair.
Install the plug in the reservoir drain hose and tighten.
Raise the operator cab. (See Raising The Operator Cab Install the motor cover.
on Page 10-30-1.)

Remove the left hydrostatic motor cover.

T300 Bobcat Loader


10-120-3 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-8

Replacing Hydraulic Fluid And Case Drain Filters


(Cont’d)

Figure 10-120-7

P-31565

Remove the hoses from the attachments case drain filter


(Item 1) [Figure 10-120-8]. Remove and discard the
1
P-31692 filter.

Install a new filter, tighten the hose fittings and install the
Remove the left side access panel (Item 1) [Figure 10- cover.
120-7].
Add the correct fluid to the reservoir until the fluid level is
at the center of the sight gauge. (See Checking And
Adding Fluid on Page 10-120-1.)

Lower the operator cab. Start the engine and operate the
loader hydraulic controls. Stop the engine. Check for
leaks. Check the fluid level in the reservoir and add as
needed.

T300 Bobcat Loader


10-120-4 Service Manual
FAN GEARBOX

Checking And Adding Oil

Figure 10-130-1

Gear Lube 1
Level

P7616

(See SERVICE SCHEDULE on Page 10-70-1.), for the


correct service interval.

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Remove the plug (Item 1) [Figure 10-130-1] to check the


lubricant level.

When checking the gearbox lube level, make sure the


level does not go above the center line of the shaft in the
gearbox [Figure 10-130-1]. Use SAE 90W gear lube if
the level is low.

T300 Bobcat Loader


10-130-1 Service Manual
T300 Bobcat Loader
10-130-2 Service Manual
POWER BOB-TACH Figure 10-131-3

Inspection And Maintenance

Figure 10-131-1

B-15177

Wedges Must Contact


Lower Edge Of Hole
In The Attachment
P-31237

If the wedge does not contact the lower edge of the hole
B-15891A (Item 1) [Figure 10-131-3], the attachment will be loose
and can come off the Bob-Tach.

Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-131-4
[Figure 10-131-1] until wedges are fully raised. Push and
hold the BOB-TACH "WEDGES DOWN" switch [Figure
10-131-1] until the wedges are fully down. The wedges
must move freely.

Figure 10-131-2

TS-1062

Inspect the mounting frame on the attachment and the


1 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-131-4]. Replace any parts including
P-31233 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-131-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-131-2] and (Item 1) [Figure 10-
131-3]. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)

T300 Bobcat Loader


10-131-1 Service Manual
T300 Bobcat Loader
10-131-2 Service Manual
BOB-TACH Figure 10-140-3

Inspection And Maintenance


Bob-Tach
Wedge

WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Wedge Must Contact
Lower Edge Of Hole
Figure 10-140-1 In the Attachment
B-15177

The spring loaded wedge (Item 1) [Figure 10-140-1]


must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-140-2] and [Figure 10-140-3].

P-21234 If the wedge does not contact the lower edge of the hole
[Figure 10-140-2] and [Figure 10-140-3], the
1 attachment will be loose and can come off the Bob-Tach.

Figure 10-140-4

P-31693

Move the Bob-Tach levers to engage the wedges [Figure


10-140-1]. The levers and wedges must move freely.

The wedges must extend through the holes in the


attachment mounting frame (Inset) [Figure 10-140-1].

Figure 10-140-2

TS-1062

Inspect the mounting frame on the attachment and the


Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-140-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for


repair or replacement parts.

Lubricate the wedges (See SERVICE SCHEDULE on


1
Page 10-70-1.) and (See LUBRICATING THE LOADER
P-31237 on Page 10-150-1.)

T300 Bobcat Loader


10-140-1 Service Manual
T300 Bobcat Loader
10-140-2 Service Manual
POWER BOB-TACH Figure 10-141-3

Inspection And Maintenance

Figure 10-141-1

B-15177

Wedges Must Contact


Lower Edge Of Hole
In The Attachment
P-31237

If the wedge does not contact the lower edge of the hole
B-15891A (Item 1) [Figure 10-141-3], the attachment will be loose
and can come off the Bob-Tach.

Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-141-4
[Figure 10-141-1] until wedges are fully raised. Push and
hold the BOB-TACH "WEDGES DOWN" switch [Figure
10-141-1] until the wedges are fully down. The wedges
must move freely.

Figure 10-141-2

TS-1062

Inspect the mounting frame on the attachment and the


1 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-141-4]. Replace any parts including
P-31233 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-141-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-141-2] and (Item 1) [Figure 10-
141-3]. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)

T300 Bobcat Loader


10-141-1 Service Manual
T300 Bobcat Loader
10-141-2 Service Manual
LUBRICATING THE LOADER Figure 10-150-3

Procedure

Figure 10-150-1 3

P-31301

3. Lift Arm Pivot Pin (Both Sides) [Figure 10-150-3].


P-31299
Figure 10-150-4

Lubricate the loader as specified in the SERVICE


SCHEDULE, Contents Page 10-01 for the best
performance of the loader.
4
Record the operating hours each time you lubricate the
Bobcat loader.

Always use a good quality lithium based multi-purpose


grease when you lubricate the loader. Apply the lubricant
until extra grease shows.

Lubricate the following locations on the loader:

1. Rod End Lift Cylinder (Both Sides) [Figure 10-150-1]. P-37665

Figure 10-150-2
4. Lift Arm Link Pivot (Both Sides) [Figure 10-150-4].
Figure 10-150-5

P-37664

P-31305
2. Base End Lift Cylinder (Both Sides) [Figure 10-150-
2].
5. Base End Tilt Cylinder (Both Sides) [Figure 10-150-
5].

T300 Bobcat Loader


10-150-1 Service Manual
LUBRICATION OF THE LOADER (CONT'D) Figure 10-150-8

Procedure (Cont'd)

Figure 10-150-6

P-31308

8. Bob-Tach Wedge (Both Sides) [[Figure 10-150-8]


P-31306
Figure 10-150-9

6. Rod End Tilt Cylinder (Both Sides) [Figure 10-150-6].

Figure 10-150-7
9

P-31304
7

9. Stabilizer Bar (Both Sides) [Figure 10-150-9].


P-31307
Figure 10-150-10

7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-150-7].

10

P-31303

10. Stabilizer Bar (Both Sides) [Figure 10-150-10].

T300 Bobcat Loader


10-150-2 Service Manual
LUBRICATION OF THE LOADER (CONT'D)

Procedure (Cont'd)

Figure 10-150-11

11

P-37666

11. 250 Hours: Steering Lever Shaft (three) [Figure 10-


150-11].

Pivot Pins

Figure 10-150-12

P-31309

All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-150-12].

Check that the lock nuts are tightened to 18-20 ft.-lb. (24-
27 N•m) torque.

T300 Bobcat Loader


10-150-3 Service Manual
T300 Bobcat Loader
10-150-4 Service Manual
HYDRAULIC SYSTEM

BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-1


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .20-90-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-2 HYDRAULIC
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . .20-90-1 SYSTEM
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-1

CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1


Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-3 DRIVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1 SYSTEM
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . .20-22-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-2 ELECTRICAL
SYSTEM &
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-6
Base Pin Removal And Installation . . . . . . . . . . . . . . . . . . . .20-21-3
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1 ENGINE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-5 SERVICE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . 20-120-1 SPECIFICATIONS


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Continued On Next Page

T300 Bobcat Loader


20-01 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL


SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . 20-41-2
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . 20-41-4
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . 20-41-30
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . 20-41-29
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-41-10
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . 20-41-14
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly20-41-13
BICS™ Valve, Lock Valve Disassembly And Assembly. . . . . . . . . . 20-41-15
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . 20-41-16
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . 20-41-28
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift Spool Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6

Continued On Next Page

T300 Bobcat Loader


20-02 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)20-40-1


Anti-Cavitation Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . 20-40-15
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Auxiliary Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Backslide, Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . 20-40-9
BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . 20-40-8
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . 20-40-7
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
BICS™ Valve, Solenoid Removal And Installation . . . . . . . . . . . . . . . 20-40-10
BICS™ Valve, Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Lift And Tilt Lock Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool And Detent Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-23
Lift Spool And Detent Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-20
Lift Spool And Detent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Lift Spool And Detent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Port-Auxiliary Section Removal And Installation . . . . . . . . . . . . . . . . . 20-40-34
Port Relief Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Tilt Spool Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)20-43-1


Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-7
Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . 20-43-28
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 20-43-26
BICS™ Valve, Check Valve Removal and Installation . . . . . . . . . . . . . 20-43-34
BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . 20-43-29
BICS™ Valve, Lock Valve Removal And Installation . . . . . . . . . . . . . . 20-43-30
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . 20-43-32
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . 20-43-6
End Cap/Spool Lock Block Removal and Installation . . . . . . . . . . . . . 20-43-13
Lift Spool and Detent Removal and Installation . . . . . . . . . . . . . . . . . . 20-43-14
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . 20-43-7
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-33
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-11
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . 20-43-8
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . 20-43-9
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . 20-43-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Rubber Boot Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-43-12
Continued On Next Page

T300 Bobcat Loader


20-03 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (SELECTABLE JOYSTICK


CONTROL) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . 20-42-2
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . . . . . . . 20-42-4
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-25
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-24
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-30
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-29
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . . . . . . . 20-42-14
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . . . . 20-42-13
BICS™ Valve, Lock Valve Disassembly And Assembly. . . . . . . . . . . . . . . . 20-42-15
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-10
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . 20-42-16
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-17
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-31
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-18
Lift And Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 20-42-28
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-19
Lift Spool Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-26
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-27
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-20
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-21
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-31
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-23
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-6

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL


SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . 20-44-6
Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-13
Auxiliary Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 20-44-27
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-25
BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . . . . 20-44-32
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . . . . 20-44-31
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . . . . 20-44-12
BICS™ Valve, Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . 20-44-29
BICS™ Valve Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . 20-44-28
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-18
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-19
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-31
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . 20-44-13
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-17
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-16
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . . . . 20-44-14
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . . . . 20-44-15
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . . . . 20-44-15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-2
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-23
Continued On Next Page
T300 Bobcat Loader
20-04 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (SELECTABLE JOYSTICK


CONTROL) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-45-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . .20-45-6
Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . .20-45-13
Auxiliary Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . .20-45-27
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . .20-45-25
BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . .20-45-32
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly .20-45-31
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . .20-45-12
BICS™ Valve, Lock Valve Removal And Installation . . . . . . . . . . . . . .20-45-29
BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . .20-45-28
End Cap Block Removal and Installation. . . . . . . . . . . . . . . . . . . . . . .20-45-18
Lift Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-45-19
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . .20-45-13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-45-31
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-45-17
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . .20-45-14
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . .20-45-15
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . .20-45-15
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-45-16
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-45-2

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1


Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-1


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-5
Check The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . .20-60-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-2

HYDRAULIC PUMP (CHARGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-1


Check The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . .20-61-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-4

Continued On Next Page

T300 Bobcat Loader


20-05 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1


Disassembly And Assembly (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . 20-62-14
Hydraulic Pump Test (30 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1
Hydraulic Pump Test (40 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-2
High Flow Relief Adjustment Procedure (30 GPM And 40 GPM) . . . . . . . . . . . 20-62-7
High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM) . . . . 20-62-9
Identification (30 GPM) (S/N 525414499 & Below) . . . . . . . . . . . . . . . . . . . . . 20-62-12
Identification (40 GPM) (S/N 525414500 & Above) . . . . . . . . . . . . . . . . . . . . . 20-62-13
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM). . . . . . . . . . . . 20-62-5
Inline Hydraulic Pump Test (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-3
Removal And Installation (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . . . . 20-62-10

HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC). . . . . . . . . . . . 20-63-1


Check The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-5
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-2

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC) 20-64-1


Disassembly And Assembly (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . 20-64-14
High Flow Relief Adjustment Procedure (30 GPM And 40 GPM) . . . . . . . . . . . 20-64-7
High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM) . . . . 20-64-9
Hydraulic Pump Test (30 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-1
Hydraulic Pump Test (40 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-2
Identification (30 GPM) (S/N 525414499 & Below) . . . . . . . . . . . . . . . . . . . . . 20-64-12
Identification (40 GPM) (S/N 525414500 & Above) . . . . . . . . . . . . . . . . . . . . . 20-64-13
Inline Hydraulic Pump Test (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-3
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM). . . . . . . . . . . . 20-64-5
Removal And Installation (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . . . . 20-64-10

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1


Tightening Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5

HYDRAULIC/HYDROSTATIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1


Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2

LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1


Additional Inspection For Loaders W/Advanced Hand Controls . . . . . . . . . . . . 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Continued On Next Page

T300 Bobcat Loader


20-06 Service Manual
HYDRAULIC SYSTEM (CONT’D)

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1


Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Checking Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4

POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

REAR AUXILIARY DIVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE


STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01)
UNLESS OTHERWISE SPECIFIED.

T300 Bobcat Loader


20-07 Service Manual
T300 Bobcat Loader
20-08 Service Manual
HYDRAULIC/HYDROSTATIC SCHEMATIC
T300 (S/N 525411001 - 525413999)
(S/N 525511001 - 525511999)
(PRINTED FEBRUARY 2005)
V-0403legend

LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 46 RELIEF VALVE - 2000 PSI (138 bar)
Capacity . . . . . . . . 21 qt. (19.9 L) (SCREEN) 21.2 GPM (80,3 L/min) at
47 SOLENOID ACTIVATED DIRECTIONAL
high engine idle
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR (ACS Valve Only) CONTROL VALVE (TWO COIL)
31 DRIVE MOTOR SHUTTLE VALVE 48 RELIEF VALVE - 1200 PSI (83 bar)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE
32 SHUTTLE RELIEF VALVE: 49 CHECK VALVE - With 80 PSI (5,5 bar)
4 SPRING LOADED FILTER BYPASS
19 RELIEF VALVE - MAIN: 200 PSI (13,8 bar) Spring
VALVE: 45-55 PSI (3,1-3,8 bar)
at Front Quick Couplers 50 CHECK VALVE - With 300 PSI (20,7 bar)
5 PILOT ACTIVATED DIRECTIONAL 33 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 bar) CONTROL VALVE - Base Spring and 0.016 inch (0,40 mm) orifice
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH 20 RELIEF VALVE - PORT: 51 ORIFICE - With 0.025 inch (0,64 mm)
34 SOLENOID ACTIVATED DIRECTIONAL
6 DIFFERENTIAL PRESSURE SWITCH: 4000 PSI (275 bar) CONTROL VALVE - Rod
36-44 PSI (2,5-3,0 bar) 21 ANTICAVITATION VALVE 52 SOLENOID ACTIVATED DIRECTIONAL
35 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE - BUCKET POSITION
7 FLOW DIVIDER ADJUSTMENT VALVE
22 RELIEF/ANTICAVITATION VALVE - VALVE (ON/OFF)
8 CHECK VALVE - BUCKET POSITION PORT (TILT BASE END) 36 PILOT ACTIVATED DIRECTIONAL 53 FILTER - CASE DRAIN (ATTACHMENT)
VALVE 3500 PSI (241 bar) CONTROL VALVE - (Two Coil)
9 FIXED CAPACITY DISPLACEMENT 23 RELIEF VALVE - PORT: 54 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC 37 PILOT ACTIVATED DIRECTIONAL
4000 PSI (275 bar) CONTROL VALVE - BRAKE
MOTOR CONTROL VALVE - REAR AUXILIARY
24 SOLENOID ACTIVATED DIRECTIONAL 55 HYDRAULIC BRAKE - SPRING APPLIED
10 PILOTED ACTIVATED DIRECTIONAL 38 ORIFICE - With 0.140 inch (3,6 mm) - PRESSURE RELEASE
CONTROL VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL
SPOOL 25 RELIEF VALVE - PORT: . . . . . (Optional) 56 ORIFICE - With 0.089 inch (2,26 mm)
39 RELIEF VALVE:
3500 PSI (241 bar)
11 PILOTED ACTIVATED DIRECTIONAL 3000 PSI (207 bar)
26 RELIEF/REPLENISHING VALVE - HIGH
CONTROL VALVE - UNLOADING 40 ORIFICE - With 0.031 inch (0,79 mm)
PRESSURE: 5000 PSI (345 bar)
SPOOL
27 PRESSURE SWITCH 41 CHECK VALVE - BICS CONTROL VALVE
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 28 RELIEF VALVE - CHARGE: 42 RESTRICTION
140 degrees F. (60 degrees C.)Fluid
13 PILOTED ACTIVATED DIRECTIONAL at high engine idle 43 CHECK VALVE
CONTROL VALVE - LIFT CONTROL 410 - 470 PSI (28,3 - 32,4 bar)
44 FRONT AUXILIARY MANUAL
14 SOLENOID ACTIVATED DIRECTIONAL 29 CHARGE PUMP:
PRESSURE BLEED-OFF VALVE
CONTROL VALVE - BICS CONTROL 14.2 GPM (53,8 L/min) at
high engine idle 45 VARIABLE CAPACITY DISPLACEMENT
15 PULL BUTTON ACTIVATED
BIDIRECTIONAL HYDROSTATIC PUMP
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS

NOTE: Unless otherwise specified


springs have NO significant
pressure value.

Printed in U.S.A. V-0403legend (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
T300 (S/N 525411001 - 525413999) FEMALE MALE
(S/N 525511001 - 525511999) (REAR QUICK
(PRINTED FEBRUARY 2005) COUPLERS)
V-0403

BASE ROD REAR AUX VALVE (OPTIONAL)

DRIVE MOTOR
INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
31 32 38
44
MALE (FRONT AUXILIARY
40
39 44 LEFT SIDE LIFT ARM)
55 37

FEMALE

9
P-OUT P-IN T

HYDRAULIC FILTER
3
BUCKET POSITION VALVE (OPTIONAL)

HYDROSTATIC PUMPS OIL


4 D
COOLER
45 8
26

28
26
7
6

5 C
HYDRAULIC CONTROL VALVE 10
27

11
26
24 24
45 25 B
A B
BOB-TACH
26 CYLINDER
(OPTIONAL) AUXILIARY
HYD.
SPOOL
30 PUMP
INLET OUTLET
18 TILT CYLINDERS
22
HYDRAULIC BICS CONTROL VALVE
POWERED
BOB-TACH
BRAKE VALVE CHARGE (OPTIONAL)
29 PUMP
OUTLET
49
DR
54
A B 12
23 TILT
50 CYLINDER
48 46 SPOOL
43 51
21
47 56
PP 18
DRIVE MOTOR
20 LIFT CYLINDERS
17
P1 P2
52 13
9

A B
LIFT
55
CYLINDER
SPOOL

18 42
31 32
2 53

19 14 WORKING CIRCUITS
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
16 41

15

Printed in U.S.A. LIFT ARM BY PASS VALVE V-0403 (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
T300 (S/N 525411001 - 525413999)
(S/N 525511001 - 525511999)
(PRINTED FEBRUARY 2005)
V-0404legend

LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 46 RELIEF VALVE - 2000 PSI (138 bar)
Capacity . . . . . . . . 21 qt. (19.9 L) (SCREEN) 21.2 GPM (80,3 L/min) at
47 SOLENOID ACTIVATED DIRECTIONAL
high engine idle
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR (ACS Valve Only) CONTROL VALVE (TWO COIL)
31 DRIVE MOTOR SHUTTLE VALVE 48 RELIEF VALVE - 1200 PSI (83 bar)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE
32 SHUTTLE RELIEF VALVE: 49 CHECK VALVE - With 80 PSI (5,5 bar)
4 SPRING LOADED FILTER BYPASS
19 RELIEF VALVE - MAIN: 200 PSI (13,8 bar) Spring
VALVE: 45-55 PSI (3,1-3,8 bar)
at Front Quick Couplers 50 CHECK VALVE - With 300 PSI (20,7 bar)
5 SOLENOID ACTIVATED DIRECTIONAL 33 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 bar) CONTROL VALVE - Base Spring and 0.016 inch (0,40 mm) orifice
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF) 20 RELIEF VALVE - PORT: 51 ORIFICE - With 0.025 inch (0,64 mm)
34 SOLENOID ACTIVATED DIRECTIONAL
6 DIFFERENTIAL PRESSURE SWITCH: 4000 PSI (275 bar) CONTROL VALVE - Rod
36-44 PSI (2,5-3,0 bar) 21 ANTICAVITATION VALVE 52 PILOT ACTIVATED DIRECTIONAL
35 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE - HYDRAULIC
7 FLOW DIVIDER ADJUSTMENT VALVE
22 RELIEF/ANTICAVITATION VALVE - POWERED BOB-TACH
8 CHECK VALVE - BUCKET POSITION PORT (TILT BASE END) 36 PILOT ACTIVATED DIRECTIONAL 53 FILTER - CASE DRAIN (ATTACHMENT)
VALVE 3500 PSI (241 bar) CONTROL VALVE - (Two Coil)
9 FIXED CAPACITY DISPLACEMENT 23 RELIEF VALVE - PORT: 54 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC 4000 PSI (275 bar) 37 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY CONTROL VALVE - BRAKE
MOTOR 24 SOLENOID ACTIVATED DIRECTIONAL 55 HYDRAULIC BRAKE - SPRING APPLIED
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY 38 ORIFICE - With 0.140 inch (3,6 mm) - PRESSURE RELEASE
CONTROL VALVE - FLOW CONTROL 25 RELIEF VALVE - PORT: . . . . . (Optional)
SPOOL 56 ORIFICE - With 0.089 inch (2,26 mm)
3500 PSI (241 bar) 39 RELIEF VALVE:
11 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH 3000 PSI (207 bar)
57 AUXILIARY HYDRAULIC PUMP
CONTROL VALVE - UNLOADING PRESSURE: 5000 PSI (345 bar) 40 ORIFICE - With 0.031 inch (0,79 mm) 10.2 GPM (38,6 L/min) at
SPOOL high engine idle
27 PRESSURE SWITCH
41 CHECK VALVE - BICS CONTROL VALVE
12 PILOTED ACTIVATED DIRECTIONAL 58 RELIEF VALVE - PORT:
28 RELIEF VALVE - CHARGE:
CONTROL VALVE - TILT CONTROL 42 RESTRICTION 3300 PSI (228 bar)
140 degrees F. (60 degrees C.)Fluid
13 PILOTED ACTIVATED DIRECTIONAL at high engine idle 43 CHECK VALVE 59 DUMP VALVE - ON/OFF
CONTROL VALVE - LIFT CONTROL 410 - 470 PSI (28,3 - 32,4 bar)
29 CHARGE PUMP: 44 FRONT AUXILIARY MANUAL 60 CHECK VALVE
14 SOLENOID ACTIVATED DIRECTIONAL 14.2 GPM (53,8 L/min) at PRESSURE BLEED-OFF VALVE
CONTROL VALVE - BICS CONTROL high engine idle
45 VARIABLE CAPACITY DISPLACEMENT
15 PULL BUTTON ACTIVATED
BIDIRECTIONAL HYDROSTATIC PUMP
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS

NOTE: Unless otherwise specified


springs have NO significant
pressure value.

Printed in U.S.A. V-0404legend (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION FEMALE MALE
(REAR QUICK
T300 (S/N 525411001 - 525413999) COUPLERS)
(S/N 525511001 - 525511999)
(PRINTED FEBRUARY 2005)
V-0404 BASE ROD REAR AUX VALVE (OPTIONAL)

DRIVE MOTOR
INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
31 32 38
44
MALE (FRONT AUXILIARY
40
39 44 LEFT SIDE LIFT ARM)
55 37

FEMALE

9
P-OUT P-IN T

HYDRAULIC FILTER
3
BUCKET POSITION VALVE (OPTIONAL)

HYDROSTATIC PUMPS OIL


4 D
COOLER
45 8
26

28
26
7
6

5 C
HYDRAULIC CONTROL VALVE 10
27

11
26
24 24
45 25 B
A B
BOB-TACH
26 CYLINDER
30 HYD. PUMP AUXILIARY
(OPTIONAL)
INLET OUTLET SPOOL
29 CHARGE PUMP
OUTLET 18 TILT CYLINDERS
22
HIGH FLOW HYDRAULIC BICS CONTROL VALVE
57 POWERED
PUMP OUTLET
BOB-TACH
(OPTIONAL)

60
58 49
DR
59
A B 12
BRAKE VALVE TILT
50 23
CYLINDER
48 46 SPOOL
51
54 21
47 56
PP 18

20 LIFT CYLINDERS
17
43 P1 P2
52 13
DRIVE MOTOR
A B
9
LIFT
CYLINDER
SPOOL

18 42

2 53

31 32 19 14 WORKING CIRCUITS
55 16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
16 41

15

Printed in U.S.A. LIFT ARM BY PASS VALVE V-0404 (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC OPTION
T300 (S/N 525411001 - 525413999)
(S/N 525511001 - 525511999)
(PRINTED FEBRUARY 2005)
V-0405legend

LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 bar)
Capacity . . . . . . . . 21 qt. (19.9 L) (SCREEN) Spring and 0.016 inch (0,40 mm) orifice
32 SHUTTLE RELIEF VALVE:
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR (ACS Valve Only) 51 ORIFICE - With 0.025 inch (0,64 mm)
200 PSI (13,8 bar)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 52 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - Base CONTROL VALVE - HYDRAULIC
4 SPRING LOADED FILTER BYPASS POWERED BOB-TACH
19 RELIEF VALVE - MAIN: 34 SOLENOID ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (3,1-3,8 bar)
at Front Quick Couplers CONTROL VALVE - Rod 53 FILTER - CASE DRAIN (ATTACHMENT)
5 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 bar)
CONTROL VALVE - BUCKET POSITION 35 LOAD SHUTTLE VALVE - BLEED OFF 54 SOLENOID ACTIVATED DIRECTIONAL
VALVE (ON/OFF) 20 RELIEF VALVE - PORT:
CONTROL VALVE - BRAKE
6 DIFFERENTIAL PRESSURE SWITCH: 4000 PSI (275 bar) 36 PILOT ACTIVATED DIRECTIONAL 55 HYDRAULIC BRAKE - SPRING APPLIED
36-44 PSI (2,5-3,0 bar) 21 ANTICAVITATION VALVE CONTROL VALVE - (Two Coil) - PRESSURE RELEASE
7 FLOW DIVIDER ADJUSTMENT VALVE
22 RELIEF/ANTICAVITATION VALVE - 37 PILOT ACTIVATED DIRECTIONAL 56 ORIFICE - With 0.089 inch (2,26 mm)
8 CHECK VALVE - BUCKET POSITION PORT (TILT BASE END) CONTROL VALVE - REAR AUXILIARY
VALVE 3500 PSI (241 bar) 57 DISPLACEMENT CONTROL VALVE
38 ORIFICE - With 0.140 inch (3,6 mm)
9 FIXED CAPACITY DISPLACEMENT 23 RELIEF VALVE - PORT:
58 PUMP SERVO
BIDIRECTIONAL HYDROSTATIC 4000 PSI (275 bar)
39 RELIEF VALVE:
MOTOR 24 SOLENOID ACTIVATED DIRECTIONAL 59 PRESSURE CONTROL PILOT VALVE
3000 PSI (207 bar)
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY (2 COILS) 0 - 0.085 Ampere
CONTROL VALVE - FLOW CONTROL 40 ORIFICE - With 0.031 inch (0,79 mm)
25 RELIEF VALVE - PORT: . . . . . (Optional)
SPOOL 3500 PSI (241 bar)
41 CHECK VALVE - BICS CONTROL VALVE
11 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH
CONTROL VALVE - UNLOADING PRESSURE: 5220 PSI (345 bar) 42 RESTRICTION
SPOOL
27 PRESSURE SWITCH 43 CHECK VALVE
12 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 44 FRONT AUXILIARY MANUAL
CONTROL VALVE - TILT CONTROL
140 degrees F. (60 degrees C.)Fluid
PRESSURE BLEED-OFF VALVE
13 PILOTED ACTIVATED DIRECTIONAL at high engine idle
CONTROL VALVE - LIFT CONTROL 330 - 360 PSI (22,7 - 24,8 bar) 45 VARIABLE CAPACITY DISPLACEMENT
29 CHARGE PUMP: BIDIRECTIONAL HYDROSTATIC PUMP
14 SOLENOID ACTIVATED DIRECTIONAL 11.1 GPM (42 L/min) (for each
CONTROL VALVE - BICS CONTROL 46 RELIEF VALVE - 2000 PSI (138 bar)
pump) at high engine idle
15 PULL BUTTON ACTIVATED 47 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT 30 HYDRAULIC PUMP . . . . . . . . . Gear Type CONTROL VALVE (TWO COIL)
ARM BY PASS 20.7 GPM (78,4 L/min) at 48 RELIEF VALVE - 1200 PSI (83 bar)
high engine idle
49 CHECK VALVE - With 80 PSI (5,5 bar)
Spring NOTE: Unless otherwise specified
springs have NO significant
pressure value.

Printed in U.S.A. V-0405legend (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC OPTION FEMALE MALE
(REAR QUICK
T300 (S/N 525411001 - 525413999) COUPLERS)
(S/N 525511001 - 525511999)
(PRINTED FEBRUARY 2005)
V-0405 BASE ROD REAR AUX VALVE (OPTIONAL)

DRIVE MOTOR
31 32 INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
55
38
44
MALE (FRONT AUXILIARY
40
9 39 44 LEFT SIDE LIFT ARM)

HYDROSTATIC M2 M1 37
PUMP
26 26 FEMALE

P-OUT P-IN T
28
CHARGE
M3 HYDRAULIC FILTER
INLET
3
29 BUCKET POSITION VALVE (OPTIONAL)
OIL
M4 4 D
COOLER
8
45
M CASE
58
5 DRAIN

7
6
57

Control
A
Module
(EDC) 5 C
HYDRAULIC CONTROL VALVE 10
59 X2
X1 27

Control X2 X1 11
Module 59
(EDC)
24 24
25 B
HYDROSTATIC A B
PUMP
BOB-TACH
CYLINDER
57 (OPTIONAL) AUXILIARY
SPOOL
M4
M 18
5 TILT CYLINDERS
58 22
45 HYDRAULIC BICS CONTROL VALVE
POWERED
CHARGE BOB-TACH
29 M3 (OPTIONAL)
INLET M3

26 26
49
CASE
28 DRAIN
A B 12
M2 23 TILT
M1 50 CYLINDER
DR 48 46 SPOOL
51
21
47 56
PP 18
HYD
BRAK PUMP 20 LIFT CYLINDERS
E 17
OUTLET P1 P2
VALVE 30 52 13
54
A B
LIFT
CYLINDER
SPOOL
DRIVE MOTOR
9 43
18 42

2 53

19 14 WORKING CIRCUITS
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
16 41
31 32

55 15

Printed in U.S.A. LIFT ARM BY PASS VALVE V-0405 (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
T300 (S/N 525411001 - 525413999)
(S/N 525511001 - 525511999)
(PRINTED FEBRUARY 2005)
V-0406legend

LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 bar)
Capacity . . . . . . . . 21 qt. (19.9 L) (SCREEN) Spring and 0.016 inch (0,40 mm) orifice
32 SHUTTLE RELIEF VALVE:
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR (ACS Valve Only) 51 ORIFICE - With 0.025 inch (0,64 mm)
200 PSI (13,8 bar)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 52 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - Base CONTROL VALVE - HYDRAULIC
4 SPRING LOADED FILTER BYPASS POWERED BOB-TACH
19 RELIEF VALVE - MAIN: 34 SOLENOID ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (3,1-3,8 bar)
at Front Quick Couplers CONTROL VALVE - Rod 53 FILTER - CASE DRAIN (ATTACHMENT)
5 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 bar)
CONTROL VALVE - BUCKET POSITION 35 LOAD SHUTTLE VALVE - BLEED OFF 54 SOLENOID ACTIVATED DIRECTIONAL
VALVE (ON/OFF) 20 RELIEF VALVE - PORT:
CONTROL VALVE - BRAKE
6 DIFFERENTIAL PRESSURE SWITCH: 4000 PSI (275 bar) 36 PILOT ACTIVATED DIRECTIONAL 55 HYDRAULIC BRAKE - SPRING APPLIED
36-44 PSI (2,5-3,0 bar) 21 ANTICAVITATION VALVE CONTROL VALVE - (Two Coil) - PRESSURE RELEASE
7 FLOW DIVIDER ADJUSTMENT VALVE
22 RELIEF/ANTICAVITATION VALVE - 37 PILOT ACTIVATED DIRECTIONAL 56 ORIFICE - With 0.089 inch (2,26 mm)
8 CHECK VALVE - BUCKET POSITION PORT (TILT BASE END) CONTROL VALVE - REAR AUXILIARY
VALVE 3500 PSI (241 bar) 57 DISPLACEMENT CONTROL VALVE
38 ORIFICE - With 0.140 inch (3,6 mm)
9 FIXED CAPACITY DISPLACEMENT 23 RELIEF VALVE - PORT:
58 PUMP SERVO
BIDIRECTIONAL HYDROSTATIC 4000 PSI (275 bar)
39 RELIEF VALVE:
MOTOR 24 SOLENOID ACTIVATED DIRECTIONAL 59 PRESSURE CONTROL PILOT VALVE
3000 PSI (207 bar)
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY (2 COILS) 0 - 0.085 Ampere
CONTROL VALVE - FLOW CONTROL 40 ORIFICE - With 0.031 inch (0,79 mm)
25 RELIEF VALVE - PORT: . . . . . (Optional) 60 AUXILIARY HYDRAULIC PUMP
SPOOL 3500 PSI (241 bar)
41 CHECK VALVE - BICS CONTROL VALVE 10.2 GPM (38,6 L/min) at
11 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH high engine idle
CONTROL VALVE - UNLOADING PRESSURE: 5220 PSI (345 bar) 42 RESTRICTION
SPOOL 61 RELIEF VALVE - PORT:
27 PRESSURE SWITCH 43 CHECK VALVE 3300 PSI (228 bar)
12 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 44 FRONT AUXILIARY MANUAL 62 DUMP VALVE - ON/OFF
CONTROL VALVE - TILT CONTROL
140 degrees F. (60 degrees C.)Fluid
PRESSURE BLEED-OFF VALVE
13 PILOTED ACTIVATED DIRECTIONAL at high engine idle 63 CHECK VALVE
CONTROL VALVE - LIFT CONTROL 330 - 360 PSI (22,7 - 24,8 bar) 45 VARIABLE CAPACITY DISPLACEMENT
29 CHARGE PUMP: BIDIRECTIONAL HYDROSTATIC PUMP
14 SOLENOID ACTIVATED DIRECTIONAL 11.1 GPM (42 L/min) (for each
CONTROL VALVE - BICS CONTROL 46 RELIEF VALVE - 2000 PSI (138 bar)
pump) at high engine idle
15 PULL BUTTON ACTIVATED 47 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT 30 HYDRAULIC PUMP . . . . . . . . . Gear Type CONTROL VALVE (TWO COIL)
ARM BY PASS 20.7 GPM (78,4 L/min) at 48 RELIEF VALVE - 1200 PSI (83 bar)
high engine idle
49 CHECK VALVE - With 80 PSI (5,5 bar)
Spring NOTE: Unless otherwise specified
springs have NO significant
pressure value.

Printed in U.S.A. V-0406legend (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION FEMALE MALE
(REAR QUICK
T300 (S/N 525411001 - 525413999) COUPLERS)
(S/N 525511001 - 525511999)
(PRINTED FEBRUARY 2005)
V-0406 BASE ROD REAR AUX VALVE (OPTIONAL)

DRIVE MOTOR
31 32 INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
55
38
44
MALE (FRONT AUXILIARY
40
9 39 44 LEFT SIDE LIFT ARM)

HYDROSTATIC M2 M1 37
PUMP
26 26 FEMALE

P-OUT P-IN T
28
CHARGE
M3 HYDRAULIC FILTER
INLET
BUCKET POSITION
3
A VALVE (OPTIONAL)
29
OIL
M4 4 D
COOLER
8
45
M CASE
58
5 DRAIN

7
6
57

Control
Module
(EDC) 5 C
HYDRAULIC CONTROL VALVE 10
59 X2
X1 27

Control X2 X1 11
Module 59
(EDC)
24 24
25 B
HYDROSTATIC A B
PUMP
BOB-TACH
CYLINDER
57 (OPTIONAL) AUXILIARY
SPOOL
M4
M 18
5 TILT CYLINDERS
58 22
45 HYDRAULIC BICS CONTROL VALVE
POWERED
CHARGE BOB-TACH
29 M3 (OPTIONAL)
INLET M3

26 26
49
CASE
28 DRAIN
A B 12
M2 23 TILT
M1 50 CYLINDER
DR 48 46 SPOOL
HYD 51
PUMP OUTLET 21
47 56
30 PP 18
BRAK OUTLET LIFT CYLINDERS
20 17
E P1 P2
VALVE 62 52 13
60
54 63
61 A B
LIFT
CYLINDER
SPOOL
DRIVE MOTOR
9 43
18 42

2 53

19 14 WORKING CIRCUITS
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
16 41
31 32

55 15

Printed in U.S.A. LIFT ARM BY PASS VALVE V-0406 (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
T300 (S/N 525414000 & Above)
(S/N 525512000 & Above)
(PRINTED FEBRUARY 2005)
V-0679legend

LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 46 RELIEF VALVE - 2000 PSI (138 bar)
Capacity . . . . . . . . 21 qt. (19.9 L) (SCREEN) 21.2 GPM (80,3 L/min) at
47 SOLENOID ACTIVATED DIRECTIONAL
high engine idle
2 FILTER - CASE DRAIN (90 Micron) 17 FILTER - BOB-TACH VALVE CONTROL VALVE (TWO COIL)
31 DRIVE MOTOR SHUTTLE VALVE 48 RELIEF VALVE - 1200 PSI (83 bar)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE
32 SHUTTLE RELIEF VALVE: 49 CHECK VALVE - With 80 PSI (5,5 bar)
4 SPRING LOADED FILTER BYPASS
19 RELIEF VALVE - MAIN: 200 PSI (13,8 bar) Spring
VALVE: 45-55 PSI (3,1-3,8 bar)
at Front Quick Couplers 50 CHECK VALVE - With 300 PSI (20,7 bar)
5 PILOT ACTIVATED DIRECTIONAL 33 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 bar) CONTROL VALVE - Base Spring and 0.016 inch (0,40 mm) orifice
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH 20 RELIEF/ANTICAVITATION VALVE - 51 ORIFICE - With 0.025 inch (0,64 mm)
34 SOLENOID ACTIVATED DIRECTIONAL
6 DIFFERENTIAL PRESSURE SWITCH: PORT (LIFT BASE END) CONTROL VALVE - Rod
36-44 PSI (2,5-3,0 bar) 4000 PSI (275 bar) 52 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE 35 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE - BUCKET POSITION
7 FLOW DIVIDER ADJUSTMENT VALVE
VALVE (ON/OFF)
8 CHECK VALVE - BUCKET POSITION 22 RELIEF/ANTICAVITATION VALVE - 36 PILOT ACTIVATED DIRECTIONAL 53 FILTER - CASE DRAIN (ATTACHMENT)
VALVE PORT (TILT BASE END) CONTROL VALVE - (Two Coil)
4000 PSI (275 bar)
9 FIXED CAPACITY DISPLACEMENT 54 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC 23 RELIEF/ANTICAVITATION VALVE - 37 PILOT ACTIVATED DIRECTIONAL
PORT (TILT ROD END) CONTROL VALVE - REAR AUXILIARY CONTROL VALVE - BRAKE
MOTOR
4000 PSI (275 bar) 55 HYDRAULIC BRAKE - SPRING APPLIED
10 PILOTED ACTIVATED DIRECTIONAL 38 ORIFICE - With 0.140 inch (3,6 mm) - PRESSURE RELEASE
CONTROL VALVE - FLOW CONTROL 24 SOLENOID ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE - AUXILIARY 56 ORIFICE - With 0.089 inch (2,26 mm)
39 RELIEF VALVE:
25 RELIEF/ANTICAVITATION VALVE - 3000 PSI (207 bar)
11 PILOTED ACTIVATED DIRECTIONAL
PORT - OPTIONAL:
CONTROL VALVE - UNLOADING 40 ORIFICE - With 0.031 inch (0,79 mm)
3100 PSI (214 bar)
SPOOL
26 RELIEF/REPLENISHING VALVE - HIGH 41 CHECK VALVE - BICS CONTROL VALVE
12 PILOTED ACTIVATED DIRECTIONAL PRESSURE: 5000 PSI (345 bar)
CONTROL VALVE - TILT CONTROL 42 RESTRICTION
27 PRESSURE SWITCH
13 PILOTED ACTIVATED DIRECTIONAL 43 CHECK VALVE
CONTROL VALVE - LIFT CONTROL 28 RELIEF VALVE - CHARGE:
140 degrees F. (60 degrees C.)Fluid 44 FRONT AUXILIARY MANUAL
14 SOLENOID ACTIVATED DIRECTIONAL at high engine idle PRESSURE BLEED-OFF VALVE
CONTROL VALVE - BICS CONTROL 410 - 470 PSI (28,3 - 32,4 bar)
45 VARIABLE CAPACITY DISPLACEMENT
15 PULL BUTTON ACTIVATED 29 CHARGE PUMP:
14.2 GPM (53,8 L/min) at BIDIRECTIONAL HYDROSTATIC PUMP
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS high engine idle

NOTE: Unless otherwise specified


springs have NO significant
pressure value.

Printed in U.S.A. V-0679legend (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
T300 (S/N 525414000 & Above) FEMALE MALE
(S/N 525512000 & Above) (REAR QUICK
(PRINTED FEBRUARY 2005) COUPLERS)
V-0679

BASE ROD REAR AUX VALVE (OPTIONAL)

DRIVE MOTOR
INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
31 32 38
44
MALE (FRONT AUXILIARY
40
39 44 LEFT SIDE LIFT ARM)
55 37

FEMALE

9
P-OUT P-IN T

HYDRAULIC FILTER
BUCKET POSITION
3 A VALVE (OPTIONAL)

HYDROSTATIC PUMPS OIL


4 D
COOLER
45 8
26

28
26
7
6

HYDRAULIC CONTROL VALVE

5 C
10
27 25

11
26
24 24
45 B
A B
BOB-TACH
26 CYLINDER
(OPTIONAL) AUXILIARY
HYD.
SPOOL
30 PUMP
INLET OUTLET
18 TILT CYLINDERS
22
HYDRAULIC BICS CONTROL VALVE
POWERED
BOB-TACH
BRAKE VALVE CHARGE (OPTIONAL)
29 PUMP
OUTLET 23
49
DR
54
A B 12
50
48 46 TILT
43 51 CYLINDER
21 SPOOL
47 56
PP 18
DRIVE MOTOR
17 LIFT CYLINDERS
20 13
9
P1 52 P2
A B
55

LIFT
CYLINDER 16 16
41
SPOOL
18 42
31 32
2 53

14 WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
19

15

Printed in U.S.A. LIFT ARM BY PASS VALVE V-0679 (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
T300 (S/N 525414000 & Above)
          (S/N 525512000 & Above)
(PRINTED MARCH 2005)
V-0680legend

LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 46 RELIEF VALVE - 2000 PSI (138 bar)
  Capacity . . . . . . . . 21 qt. (19.9 L)   (SCREEN)         21.2 GPM (80,3 L/min) at
47 SOLENOID ACTIVATED DIRECTIONAL
high engine idle
2 FILTER - CASE DRAIN (90 Micron) 17 FILTER - BOB-TACH VALVE   CONTROL VALVE (TWO COIL)
31 DRIVE MOTOR SHUTTLE VALVE 48 RELIEF VALVE - 1200 PSI (83 bar)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE
32 SHUTTLE RELIEF VALVE: 49 CHECK VALVE - With 80 PSI (5,5 bar)
4 SPRING LOADED FILTER BYPASS
19 RELIEF VALVE - MAIN:                                      200 PSI (13,8 bar) Spring
  VALVE:  45-55 PSI (3,1-3,8 bar)
                          at Front Quick Couplers 50 CHECK VALVE - With 300 PSI (20,7 bar)
5 SOLENOID ACTIVATED DIRECTIONAL 33 SOLENOID ACTIVATED DIRECTIONAL
           3250-3350 PSI (224-231 bar)   CONTROL VALVE - Base Spring and 0.016 inch (0,40 mm) orifice
  CONTROL VALVE - BUCKET POSITION
  VALVE (ON/OFF) 20 RELIEF/ANTICAVITATION VALVE - 51 ORIFICE - With 0.025 inch (0,64 mm)
34 SOLENOID ACTIVATED DIRECTIONAL
6 DIFFERENTIAL PRESSURE SWITCH:   PORT (LIFT BASE END)   CONTROL VALVE - Rod
                           4000 PSI (275 bar) 52 PILOT ACTIVATED DIRECTIONAL
                     36-44 PSI (2,5-3,0 bar)   CONTROL VALVE - HYDRAULIC
21 ANTICAVITATION VALVE 35 LOAD SHUTTLE VALVE - BLEED OFF
7 FLOW DIVIDER ADJUSTMENT VALVE   POWERED BOB-TACH
8 22 RELIEF/ANTICAVITATION VALVE - 53 FILTER - CASE DRAIN (ATTACHMENT)
CHECK VALVE - BUCKET POSITION 36 PILOT ACTIVATED DIRECTIONAL
   VALVE   PORT (TILT BASE END)   CONTROL VALVE - (Two Coil)
                           4000 PSI (275 bar) 54 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - BRAKE
  BIDIRECTIONAL HYDROSTATIC 23 RELIEF/ANTICAVITATION VALVE - 37 PILOT ACTIVATED DIRECTIONAL
  PORT (TILT ROD END)   CONTROL VALVE - REAR AUXILIARY 55 HYDRAULIC BRAKE - SPRING APPLIED
  MOTOR
                           4000 PSI (275 bar) - PRESSURE RELEASE
10 PILOTED ACTIVATED DIRECTIONAL 38 ORIFICE - With 0.140 inch (3,6 mm)
  CONTROL VALVE - FLOW CONTROL 24 SOLENOID ACTIVATED DIRECTIONAL 56 ORIFICE - With 0.089 inch (2,26 mm)
  SPOOL   CONTROL VALVE - AUXILIARY 39 RELIEF VALVE: 57 AUXILIARY HYDRAULIC PUMP
11 PILOTED ACTIVATED DIRECTIONAL 25 RELIEF/ANTICAVITATION VALVE -                              3000 PSI (207 bar)
  CONTROL VALVE - UNLOADING   PORT - OPTIONAL:    
40 ORIFICE - With 0.031 inch (0,79 mm) S/N 525414000 - 525414499
  SPOOL                            3100 PSI (214 bar)
S/N 525512000 - 525512099
26 RELIEF/REPLENISHING VALVE - HIGH 41 CHECK VALVE - BICS CONTROL VALVE         10.5 GPM (39,7 L/min) at High Engine Idle
12 PILOTED ACTIVATED DIRECTIONAL
     PRESSURE:      5000 PSI (345 bar)
  CONTROL VALVE - TILT CONTROL 42 RESTRICTION S/N 525414500 & Above
27 PRESSURE SWITCH S/N 525512100 & Above
13 PILOTED ACTIVATED DIRECTIONAL 43 CHECK VALVE
  CONTROL VALVE - LIFT CONTROL 28         18.7 GPM (70,8 L/min) at High Engine Idle
RELIEF VALVE - CHARGE:
       140 degrees F. (60 degrees C.)Fluid 44 FRONT AUXILIARY MANUAL
14 SOLENOID ACTIVATED DIRECTIONAL                                    at high engine idle   PRESSURE BLEED-OFF VALVE 58 RELIEF VALVE - PORT:
  CONTROL VALVE - BICS CONTROL               410 - 470 PSI (28,3 - 32,4 bar)                              3300 PSI (228 bar)
45 VARIABLE CAPACITY DISPLACEMENT 59    
DUMP VALVE - ON/OFF
15 PULL BUTTON ACTIVATED 29 CHARGE PUMP:   BIDIRECTIONAL HYDROSTATIC PUMP
  DIRECTIONAL CONTROL VALVE - LIFT           14.2 GPM (53,8 L/min) at
  ARM BY PASS 60 CHECK VALVE
high engine idle

NOTE: Unless otherwise specified
             springs have NO significant
             pressure value.

Printed in U.S.A. V-0680legend (3-9-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION FEMALE MALE
(REAR QUICK
T300 (S/N 525414000 & Above) COUPLERS)
(S/N 525512000 & Above)
(PRINTED MARCH 2005)
V-0680 BASE ROD REAR AUX VALVE (OPTIONAL)

DRIVE MOTOR
INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
31 32 38
44
MALE (FRONT AUXILIARY
40
39 44 LEFT SIDE LIFT ARM)
55 37

FEMALE

9
P-OUT P-IN T

HYDRAULIC FILTER
BUCKET POSITION
3 VALVE (OPTIONAL)
A

HYDROSTATIC PUMPS OIL


4 D
COOLER
45 8
26

28
26
7
6

HYDRAULIC CONTROL VALVE

5 C
10
27 25

11
26
24 24
45 B
A B
BOB-TACH
26 CYLINDER
30 HYD. PUMP AUXILIARY
(OPTIONAL)
INLET OUTLET SPOOL

29 CHARGE PUMP
OUTLET 18 TILT CYLINDERS
22
HIGH FLOW HYDRAULIC BICS CONTROL VALVE
57 POWERED
PUMP OUTLET
BOB-TACH
(OPTIONAL)

60
58 49 23
DR
59
A B 12
BRAKE VALVE
50

48 46 TILT
51 CYLINDER
54
47 56 21 SPOOL
PP 18
LIFT CYLINDERS
17
43 P1
20 13
DRIVE MOTOR
P2
52 A B
9

LIFT
CYLINDER 16
16 41
SPOOL
18 42

2 53

31 32 14 WORKING CIRCUITS
55 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
19

15

Printed in U.S.A. LIFT ARM BY PASS VALVE V-0680 (3-9-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC OPTION
T300 (S/N 525414000 & Above)
(S/N 525512000 & Above)
(PRINTED FEBRUARY 2005)
V-0681legend

LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 bar)
Capacity . . . . . . . . 21 qt. (19.9 L) (SCREEN) Spring and 0.016 inch (0,40 mm) orifice
32 SHUTTLE RELIEF VALVE:
2 FILTER - CASE DRAIN (90 Micron) 17 FILTER - BOB-TACH VALVE 51 ORIFICE - With 0.025 inch (0,64 mm)
200 PSI (13,8 bar)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 52 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - Base CONTROL VALVE - HYDRAULIC
4 SPRING LOADED FILTER BYPASS POWERED BOB-TACH
19 RELIEF VALVE - MAIN: 34 SOLENOID ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (3,1-3,8 bar)
at Front Quick Couplers CONTROL VALVE - Rod 53 FILTER - CASE DRAIN (ATTACHMENT)
5 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 bar)
CONTROL VALVE - BUCKET POSITION 35 LOAD SHUTTLE VALVE - BLEED OFF 54 SOLENOID ACTIVATED DIRECTIONAL
VALVE (ON/OFF) 20 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - BRAKE
6 DIFFERENTIAL PRESSURE SWITCH: PORT (LIFT BASE END) 36 PILOT ACTIVATED DIRECTIONAL 55 HYDRAULIC BRAKE - SPRING APPLIED
36-44 PSI (2,5-3,0 bar) 4000 PSI (275 bar) CONTROL VALVE - (Two Coil) - PRESSURE RELEASE
7 FLOW DIVIDER ADJUSTMENT VALVE 21 ANTICAVITATION VALVE
37 PILOT ACTIVATED DIRECTIONAL 56 ORIFICE - With 0.089 inch (2,26 mm)
8 CHECK VALVE - BUCKET POSITION 22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - REAR AUXILIARY
VALVE 57 DISPLACEMENT CONTROL VALVE
PORT (TILT BASE END)
4000 PSI (275 bar) 38 ORIFICE - With 0.140 inch (3,6 mm)
9 FIXED CAPACITY DISPLACEMENT 58 PUMP SERVO
BIDIRECTIONAL HYDROSTATIC 23 RELIEF/ANTICAVITATION VALVE - 39 RELIEF VALVE:
MOTOR PORT (TILT ROD END) 59 PRESSURE CONTROL PILOT VALVE
3000 PSI (207 bar)
10 PILOTED ACTIVATED DIRECTIONAL 4000 PSI (275 bar) (2 COILS) 0 - 0.085 Ampere
CONTROL VALVE - FLOW CONTROL 40 ORIFICE - With 0.031 inch (0,79 mm)
24 SOLENOID ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE - AUXILIARY 41 CHECK VALVE - BICS CONTROL VALVE
11 PILOTED ACTIVATED DIRECTIONAL 25 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - UNLOADING PORT - OPTIONAL: 42 RESTRICTION
SPOOL 3100 PSI (214 bar)
43 CHECK VALVE
12 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH
CONTROL VALVE - TILT CONTROL PRESSURE: 5220 PSI (345 bar) 44 FRONT AUXILIARY MANUAL
27 PRESSURE SWITCH PRESSURE BLEED-OFF VALVE
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 45 VARIABLE CAPACITY DISPLACEMENT
28 RELIEF VALVE - CHARGE:
140 degrees F. (60 degrees C.)Fluid BIDIRECTIONAL HYDROSTATIC PUMP
14 SOLENOID ACTIVATED DIRECTIONAL
at high engine idle 46 RELIEF VALVE - 2000 PSI (138 bar)
CONTROL VALVE - BICS CONTROL
330 - 360 PSI (22,7 - 24,8 bar)
15 PULL BUTTON ACTIVATED 47 SOLENOID ACTIVATED DIRECTIONAL
29 CHARGE PUMP:
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE (TWO COIL)
11.1 GPM (42 L/min) (for each
ARM BY PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
pump) at high engine idle
49 CHECK VALVE - With 80 PSI (5,5 bar)
30 HYDRAULIC PUMP . . . . . . . . . Gear Type
Spring NOTE: Unless otherwise specified
20.7 GPM (78,4 L/min) at
springs have NO significant
high engine idle
pressure value.

Printed in U.S.A. V-0681legend (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC OPTION FEMALE MALE
(REAR QUICK
T300 (S/N 525414000 & Above) COUPLERS)
(S/N 525512000 & Above)
(PRINTED FEBRUARY 2005)
V-0681 BASE ROD REAR AUX VALVE (OPTIONAL)

DRIVE MOTOR
31 32 INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
55
38
44
MALE (FRONT AUXILIARY
40
9 39 44 LEFT SIDE LIFT ARM)

HYDROSTATIC M2 M1 37
PUMP
26 26 FEMALE

P-OUT P-IN T
28
CHARGE
M3 HYDRAULIC FILTER
INLET
BUCKET POSITION
3 A VALVE (OPTIONAL)
29
OIL
M4 4 D
COOLER
8
45
M CASE
58
5 DRAIN

7
6
57

Control HYDRAULIC CONTROL VALVE


Module
(EDC) 5 C
59 10
X1 X2 27
25

Control X2 X1 11
Module 59
(EDC)
24 24
B
HYDROSTATIC A B
BOB-TACH
PUMP
CYLINDER
(OPTIONAL)
57 AUXILIARY
SPOOL
M4
M 18
HYDRAULIC TILT CYLINDERS
5 22
58 POWERED
45 BICS CONTROL VALVE
BOB-TACH
(OPTIONAL)
CHARGE
29 M3
INLET M3
49
26 26
23
CASE
28 DRAIN
A B 12
M2
M1 48 46 50
51
DR TILT
47 56 CYLINDER
PP 21 SPOOL
17 18
HYD
BRAK PUMP LIFT CYLINDERS
E P1 P2
OUTLET 52
VALVE 30 20 13
54
A B

LIFT
DRIVE MOTOR CYLINDER
43 SPOOL 16 41
9
18 42

2 53

14 WORKING CIRCUITS
16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
19
31 32

55 15

Printed in U.S.A. LIFT ARM BY PASS VALVE V-0681 (2-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
T300 (S/N 525414000 & Above)
         (S/N 525512000 & Above)
(PRINTED MARCH 2005)
V-0682legend

LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 bar)
  Capacity . . . . . . . . 21 qt. (19.9 L)   (SCREEN) Spring and 0.016 inch (0,40 mm) orifice
32 SHUTTLE RELIEF VALVE:
2 FILTER - CASE DRAIN (90 Micron) 17 FILTER - BOB-TACH VALVE 51 ORIFICE - With 0.025 inch (0,64 mm)
                                     200 PSI (13,8 bar)
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL 52 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - Base   CONTROL VALVE - HYDRAULIC
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN:   POWERED BOB-TACH
  VALVE:  45-55 PSI (3,1-3,8 bar) 34 SOLENOID ACTIVATED DIRECTIONAL 53 FILTER - CASE DRAIN (ATTACHMENT)
                          at Front Quick Couplers
  CONTROL VALVE - Rod
5 SOLENOID ACTIVATED DIRECTIONAL            3250-3350 PSI (224-231 bar) 54 SOLENOID ACTIVATED DIRECTIONAL
  CONTROL VALVE - BUCKET POSITION 35 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE - BRAKE
  VALVE (ON/OFF) 20 RELIEF/ANTICAVITATION VALVE -
  PORT (LIFT BASE END) 55 HYDRAULIC BRAKE - SPRING APPLIED
6 DIFFERENTIAL PRESSURE SWITCH: 36 PILOT ACTIVATED DIRECTIONAL - PRESSURE RELEASE
                           4000 PSI (241 bar)
                     36-44 PSI (2,5-3,0 bar)   CONTROL VALVE - (Two Coil)
21 ANTICAVITATION VALVE 56 ORIFICE - With 0.089 inch (2,26 mm)
7 FLOW DIVIDER ADJUSTMENT VALVE
37 PILOT ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION 22 RELIEF/ANTICAVITATION VALVE -   CONTROL VALVE - REAR AUXILIARY 57 DISPLACEMENT CONTROL VALVE
   VALVE   PORT (TILT BASE END)
                           4000 PSI (241 bar) 38 ORIFICE - With 0.140 inch (3,6 mm) 58 PUMP SERVO
9 FIXED CAPACITY DISPLACEMENT
  BIDIRECTIONAL HYDROSTATIC 23 RELIEF/ANTICAVITATION VALVE - 59 PRESSURE CONTROL PILOT VALVE
39 RELIEF VALVE:
  MOTOR   PORT (TILT ROD END) (2 COILS)                  0 - 0.085 Ampere
                             3000 PSI (207 bar)
10 PILOTED ACTIVATED DIRECTIONAL                            4000 PSI (241 bar)    
40 ORIFICE - With 0.031 inch (0,79 mm) 60 AUXILIARY HYDRAULIC PUMP
  CONTROL VALVE - FLOW CONTROL 24 SOLENOID ACTIVATED DIRECTIONAL
  SPOOL   CONTROL VALVE - AUXILIARY 41 CHECK VALVE - BICS CONTROL VALVE S/N 525414000 - 525414499
11 PILOTED ACTIVATED DIRECTIONAL 25 RELIEF/ANTICAVITATION VALVE - S/N 525512000 - 525512099
  CONTROL VALVE - UNLOADING 42 RESTRICTION         10.5 GPM (39,7 L/min) at High Engine Idle
  PORT - OPTIONAL:
  SPOOL                            3100 PSI (214 bar)
43 CHECK VALVE S/N 525414500 & Above
12 PILOTED ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH S/N 525512100 & Above
  CONTROL VALVE - TILT CONTROL      PRESSURE:      5220 PSI (345 bar) 44 FRONT AUXILIARY MANUAL         18.7 GPM (70,8 L/min) at High Engine Idle
  PRESSURE BLEED-OFF VALVE
13 PILOTED ACTIVATED DIRECTIONAL 27 PRESSURE SWITCH
45 61 RELIEF VALVE - PORT:
  CONTROL VALVE - LIFT CONTROL VARIABLE CAPACITY DISPLACEMENT
28 RELIEF VALVE - CHARGE:   BIDIRECTIONAL HYDROSTATIC PUMP                              3300 PSI (228 bar)
14 SOLENOID ACTIVATED DIRECTIONAL        140 degrees F. (60 degrees C.)Fluid 62    
DUMP VALVE - ON/OFF
  CONTROL VALVE - BICS CONTROL                                    at high engine idle 46 RELIEF VALVE - 2000 PSI (138 bar)
              330 - 360 PSI (22,7 - 24,8 bar) 63 CHECK VALVE
15 PULL BUTTON ACTIVATED 47 SOLENOID ACTIVATED DIRECTIONAL
  DIRECTIONAL CONTROL VALVE - LIFT 29 CHARGE PUMP:   CONTROL VALVE (TWO COIL)
  ARM BY PASS           11.1 GPM (42 L/min) (for each 48 RELIEF VALVE - 1200 PSI (83 bar)
               pump) at high engine idle
49 CHECK VALVE - With 80 PSI (5,5 bar)
30 HYDRAULIC PUMP . . . . . . . . . Gear Type Spring NOTE: Unless otherwise specified
        20.7 GPM (78,4 L/min) at              springs have NO significant
high engine idle              pressure value.

Printed in U.S.A. V-0682legend (3-9-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION FEMALE MALE
(REAR QUICK
T300 (S/N 525414000 & Above) COUPLERS)
(S/N 525512000 & Above)
(PRINTED MARCH 2005)
V-0682 BASE ROD REAR AUX VALVE (OPTIONAL)

DRIVE MOTOR
31 32 INTEGRATED QUICK COUPLER BLOCK
33 34
MALE
35
36
55
38
44
MALE (FRONT AUXILIARY
40
9 39 44 LEFT SIDE LIFT ARM)

HYDROSTATIC M2 M1 37
PUMP
26 26 FEMALE

HYDRAULIC FILTER P-OUT P-IN T


28
CHARGE 3
M3
INLET
BUCKET POSITION
4 A VALVE (OPTIONAL)
29
OIL
M4 COOLER D
8
45
M CASE
58
5 DRAIN
6
7

57
HYDRAULIC CONTROL VALVE
Control
Module
(EDC) 5 C
59 10
X1 X2 27 25

Control X2 X1 11
Module 59
(EDC)
24 24
B
HYDROSTATIC A B
PUMP
BOB-TACH
CYLINDER
(OPTIONAL) AUXILIARY
57
SPOOL
M4
M 18
5 TILT CYLINDERS
58 22
45 HYDRAULIC BICS CONTROL VALVE
POWERED
CHARGE BOB-TACH
29 M3 (OPTIONAL)
INLET M3

26 26
49
CASE 23
28 DRAIN
A B 12
M2
M1 50
DR 48 46
51 TILT
HYD
CYLINDER
PUMP OUTLET 21
47 56 SPOOL
30 PP 18
BRAK OUTLET LIFT CYLINDERS
E 17
VALVE 62 13
60 20
54 63
61 P1 P2 A B
52

LIFT
DRIVE MOTOR
CYLINDER 16 16
43 41
9 SPOOL
18 42

2 53

14 WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
19
31 32

55 15

Printed in U.S.A. LIFT ARM BY PASS VALVE V-0682 (3-9-05)


HYDRAULIC SYSTEM INFORMATION

T300 Bobcat Loader


20-10-1 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)

T300 Bobcat Loader


20-10-2 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)

T300 Bobcat Loader


20-10-3 Service Manual
T300 Bobcat Loader
20-10-4 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285

If the service code appears in the left instrument panel,


refer to the Electrical Service Manual for the probable
cause.

PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light comes ON when hydraulics are operating. 1, 3
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
By-pass valve stuck. 12
By-pass valve stem bent or broke. 13

KEY TO CORRECT THE CAUSE


1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See LOADER SPECIFICATIONS (T300) on Page SPEC-10-1.)
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace manual spool cartridge.

T300 Bobcat Loader


20-10-5 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)

Tightening Procedure

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

For Tightening Torques For Hydraulic Fittings, Tubelines,


etc., (See HYDRAULIC CONNECTION
SPECIFICATIONS on Page SPEC-40-1.)

T300 Bobcat Loader


20-10-6 Service Manual
CYLINDER (LIFT) Install a cap (Item 1) [Figure 20-20-2] in the hose and
tighten.
Checking
Engage the parking brake. Lower the seat bar. Start the
Figure 20-20-1 engine and push the top (toe) of the lift pedal.

If there is any leakage from the fitting on the cylinder


(Item 2) [Figure 20-20-2]. Remove the lift cylinder for
repair. Repeat the procedure to check the other lift
cylinder.

1 Removal And Installation

Figure 20-20-3

P-31363
1

Lower the lift arms. Stop the engine. Raise the seat bar.

WARNING
Hydraulic fluid escaping under pressure can have P-31363
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
Disconnect both hydraulic hoses from the cylinder (Item
and possibly death if proper medical treatment by a
1) [Figure 20-20-3]. Cap and plug the fittings and hoses.
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-20-4

Check only one cylinder at a time. Disconnect the hose


(Item 1) [Figure 20-20-1] which goes to the base end of
the lift cylinder.

Figure 20-20-2
1

1
2

P-31365

Remove the retaining bolt and nut (Item 1) [Figure 20-


20-4] from the retaining pin on the rod end of the lift
cylinder.

P-31364 Installation: Tighten the retainer bolt and nut to 18-20 ft.-
lb. (24-27 N•m) torque.

T300 Bobcat Loader


20-20-1 Service Manual
CYLINDER (LIFT) (CONT'D) Figure 20-20-7

Removal And Installation (Cont'd)

Figure 20-20-5

1
P-31368
1

Install a slide hammer (Item 1) [Figure 20-20-7] and


P-31366 remove the base end pivot pin.

Remove the lift cylinder.


Install a slide hammer (Item 1) [Figure 20-20-5] and
remove the retaining pin from the rod end of the cylinder.

Figure 20-20-6
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
1

P-31367

Remove the retaining bolt and nut (Item 1) [Figure 20-


20-6] from the pivot pin at the base end of the lift cylinder.

Installation: Tighten the retainer bolt and nut to 18-20 ft.-


lb. (24-27 N•m) torque.

T300 Bobcat Loader


20-20-2 Service Manual
CYLINDER (LIFT) (CONT'D)

Parts Identification

1. Case 9. Spacer
2. Piston 10. Washer
3. Head 11. O-ring
4. Rod 12. Seal
5. O-ring 13. Seal
6. Nut 14. Plug
7. Seal 15. O-ring
8. O-ring 16. Tapeline

7 4

14 15

TS-1060a
TS-1060a

1
13

16
3

11

10

12
14 15

TS-1060b PE1519A

T300 Bobcat Loader


20-20-3 Service Manual
CYLINDER (LIFT) (CONT'D) Figure 20-20-10

Disassembly
2
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook 1


Spanner Wrench

Hold the hydraulic cylinder over a drain pan and move


the rod in and out slowly to remove the fluid from the
cylinder.

Put the base end of the cylinder in a vise. 3

Figure 20-20-8 P-48038

1 Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-


20-10] from the piston.

NOTE: If the fiber surface (Item 3) [Figure 20-20-10] on


the piston head, becomes damaged, the
complete piston head must be replaced.

Figure 20-20-11

P-48033

Use a spanner wrench to loosen the head (Item 1)


[Figure 20-20-8] from the cylinder case.
2
Figure 20-20-9

4
3 P-48039
2

1 Remove the two O-rings (Item 1) and the back-up washer


(Item 2) [Figure 20-20-11] from the cylinder head.

P-48036

Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-9].

T300 Bobcat Loader


20-20-4 Service Manual
CYLINDER (LIFT) (CONT'D) Assembly

Disassembly (Cont'd) Use the following tools to assemble the cylinder:

Figure 20-20-12 MEL1396 - Seal Installation Tool


MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench

1 Figure 20-20-14

P-48040

Remove the wiper seal (Item 1) [Figure 20-20-12] from


the cylinder head.
P7424
Figure 20-20-13

Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other


damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.


1
Lubricate all O-rings and seals with hydraulic oil during
installation.

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-14].

P-48042 Allow the seal to stretch for 30 seconds before installing it


on the piston.
Remove the rod seal (Item 1) [Figure 20-20-13] from the
cylinder head.

T300 Bobcat Loader


20-20-5 Service Manual
CYLINDER (LIFT) (CONT'D) Figure 20-20-17

Assembly (Cont'd)

Figure 20-20-15

1
2

P7425

Install the rod seal in the head [Figure 20-20-17].


P-48038
Figure 20-20-18

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-


20-15] on the cylinder piston.
2
Figure 20-20-16

P-48041 P-48042

Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-20-
P-48043 P7427 18].

Install the rod seal on the rod seal tool [Figure 20-20-16].

NOTE: During installation the spring side of the seal


(Item 1) [Figure 20-20-16] must be installed
toward the inside of the cylinder.

Rotate the handles to collapse the rod seal [Figure 20-


20-16].

T300 Bobcat Loader


20-20-6 Service Manual
CYLINDER (LIFT) (CONT'D)

Assembly (Cont'd)

Figure 20-20-19

1
2 3

P-48036

NOTE: Clean and dry the threads before installing the


nut. Install the new nut from the kit.

Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-19].

Tighten the nut (Item 4) [Figure 20-20-19] to 600 ft.-lb.


(814 N•m) torque.

Figure 20-20-20

P-48035

Put the base end of the hydraulic cylinder in a vise.

Using a spanner wrench, tighten the head (Item 1)


[Figure 20-20-20] until the head is flush with the end of
the cylinder tube assembly.

T300 Bobcat Loader


20-20-7 Service Manual
T300 Bobcat Loader
20-20-8 Service Manual
CYLINDER (TILT) Install a cap (Item 1) [Figure 20-21-2] in the hydraulic
hose and tighten.
Checking
Engage the parking brake. Lower the seat bar. Start the
Figure 20-21-1 engine and push the bottom (heel) of the tilt pedal. If
there is leakage from the open port on the cylinder (Item
2) [Figure 20-21-2], remove the tilt cylinder for repair.

Repeat procedure to check the other tilt cylinder.

Removal And Installation

Figure 20-21-3

P-31369

Remove the attachment. Roll the Bob-Tach fully back.


Stop the engine. Raise the seat bar. 1

WARNING P-31371

Hydraulic fluid escaping under pressure can have


Remove the attachment from the Bob-Tach. Roll the Bob-
sufficient force to enter a person’s body by
Tach forward
penetrating the skin. This can cause serious injury
and possibly death if proper medical treatment by a Stop the engine. Raise the seat bar.
physician familiar with this injury is not received
Remove the retainer bolt and nut (Item 1) [Figure 20-21-
immediately.
W-2145-0290
3] from the rod end pivot pin.

Installation: Tighten the retainer nut to 18-20 ft.-lb. (24-


Disconnect the hose (Item 1) [Figure 20-21-1] which 27 N•m) torque.
goes to the base end of the tilt cylinder.
Figure 20-21-4
Figure 20-21-2

1
2
1

P-31372
P-31370

Remove the rod end pivot pin (Item 1) [Figure 20-21-4].


T300 Bobcat Loader
20-21-1 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-7

Removal And Installation (Cont'd)

Figure 20-21-5

1
P-31374

Remove the base end pivot bolt and washer (Item 1)


P-31369 [Figure 20-21-7].

Figure 20-21-8
Disconnect the two hydraulic hoses (Items 1 & 2) [Figure
20-21-5] from the tilt cylinder.

Cap the hoses and plug the fittings on the cylinder.

Figure 20-21-6

P-31375

Slide the cylinder from the base pin and remove the tilt
cylinder from the loader [Figure 20-21-8].

P-31373

Remove the retainer nut (Item 1) [Figure 20-21-6] from


the base end pivot pin.

Installation: Tighten the retainer nut to 190 ft.-lb. (257,6


N•m) torque.

T300 Bobcat Loader


20-21-2 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-11

Base Pin Removal And Installation

Figure 20-21-9

P-31378

1
Check pivot pin and replace as needed [Figure 20-21-
P-31376 11].

Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-9]. (See Removal And Installation on
Page 20-21-1.)

Figure 20-21-10

P-31377

Use a 7/8” (.875 mm) shaft (Item 1) [Figure 20-21-10]


and a hammer to remove the tilt cylinder base pin from
the lift arms.

T300 Bobcat Loader


20-21-3 Service Manual
CYLINDER (TILT) (CONT'D)

Parts Identification

1. Case 9. O-ring
2. Piston 10. Washer
3. Head 11. O-ring
4. Rod 12. Seal
5. Bushing 13. Seal
6. Nut 14. Plug
7. O-ring 15. O-ring
8. Seal 16. Tubeline TS-1688b

12

9
1
15
10
14

16
11

15 6
3
14

2 13

4
8

TS-1688a PE1520A
TS-1060a

T300 Bobcat Loader


20-21-4 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-14

Disassembly
2
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook 1


Spanner Wrench

Hold the hydraulic cylinder over a drain pan and move


the rod in and out slowly to remove the fluid from the
cylinder.

Put the base end of the cylinder in a vise.

Figure 20-21-12 P-48073

Remove the seal (Item 1), and O-ring (Item 2) [Figure


20-21-14] from the piston.
1
Figure 20-21-15

2
P-48034

Use a spanner wrench to loosen the head (Item 1)


[Figure 20-21-12] from the cylinder case.

Figure 20-21-13 P-48039

3 Remove the two O-rings (Item 1) and the back-up washer


2 (Item 2) [Figure 20-21-15] from the cylinder head.

P-48071

Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13].

T300 Bobcat Loader


20-21-5 Service Manual
CYLINDER (TILT) (CONT'D) Assembly

Disassembly (Cont'd) Use the following tools to assemble the cylinder:

Figure 20-21-16 MEL1396 - Seal Installation Tool


MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench

1 Figure 20-21-18

P-48040

Remove the wiper seal (Item 1) [Figure 20-21-16] from


the cylinder head.
P7424
Figure 20-21-17

Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other


damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.


1
Lubricate all O-rings and seals with hydraulic oil during
installation.

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-18].

P-48042 Allow the seal to stretch for 30 seconds before installing it


on the piston.
Remove the rod seal (Item 1) [Figure 20-21-17] from the
cylinder head.

T300 Bobcat Loader


20-21-6 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-21

Assembly (Cont'd)

Figure 20-21-19

P7425

Install the rod seal in the head [Figure 20-21-21].


P-48073
Figure 20-21-22

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-


21-19] on the cylinder piston.
2
Figure 20-21-20

P-48041 P-48042

Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-21-
P-48043 P7427 22].

Install the rod seal on the rod seal tool [Figure 20-21-20].

NOTE: During installation the spring side of the seal


(Item 1) [Figure 20-21-20] must be installed
toward the inside of the cylinder.

Rotate the handles to collapse the rod seal [Figure 20-


21-20].

T300 Bobcat Loader


20-21-7 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-25

Assembly (Cont'd)

Figure 20-21-23
1

1
2

P-48070

Put the base end of the hydraulic cylinder in a vise.


P-48071
Using a spanner wrench, tighten the head (Item 1)
[Figure 20-21-25] until the head is flush with the end of
NOTE: Clean and dry the threads before installing the the cylinder tube assembly.
nut. Install the new nut from the kit.

Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-23].

Tighten the nut (Item 3) [Figure 20-21-23] to 100 ft.-lb.


(136 N•m) torque.

Figure 20-21-24

P-48088 P-48089

Mark the end of the shaft and nut [Figure 20-21-24].


Tighten the nut an additional 135 degrees or 2-1/4 flats
[Figure 20-21-24].

T300 Bobcat Loader


20-21-8 Service Manual
CYLINDER (POWER BOB-TACH) Figure 20-22-3

Checking

WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece or cardboard or wood to find leaks. Do 2
not use your bare hand. Wear safety goggles. If fluid 1
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496 P-31381

Figure 20-22-1 Install a plug in the hose (Item 1) [Figure 20-22-3] and
tighten.

Engage the parking brake. Lower the seat bar. Start the
engine.

Push and hold the BOB-TACH "WEDGES UP" Switch


(Front Accessory Panel).

If there is any leakage from the base end cylinder port


(Item 2) [Figure 20-22-3], remove the lift cylinder for
repair.

P-31379
WARNING
Tilt the Bob-Tach forward, so it is parallel to the floor Always clean up spilled fuel or oil. Keep heat, flames,
[Figure 20-22-1]. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Figure 20-22-2 explosion or fire which can result in injury or death.
W-2103-1285

P-31380

Disconnect the hose (Item 1) [Figure 20-22-2] from the


power Bob-Tach cylinder base end port.

T300 Bobcat Loader


20-22-1 Service Manual
CYLINDER (POWER BOB-TACH)

Removal And Installation

Figure 20-22-4

1 1
P-31379

Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].

Install plugs in the hoses and cap on fittings.

Figure 20-22-5

1
1

P-31382

Remove the bolts and washers (Item 1) [Figure 20-22-


5].

Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 N•m)


torque.

Remove the cylinder from the lever pivots.

T300 Bobcat Loader


20-22-2 Service Manual
CYLINDER (POWER BOB-TACH) (CONT'D)

Parts Identification

1. Cylinder 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring

2 3
4
5
6

7
8 9
10
11
12

13

B-16207

T300 Bobcat Loader


20-22-3 Service Manual
CYLINDER (POWER BOB-TACH) (CONT'D) Figure 20-22-8

Disassembly 3 2 1
Figure 20-22-6

1 P16295

Piston: Remove the O-ring (Item 1), and seal (Item 2)


P16293 from the piston (Item 3) [Figure 20-22-8].

Figure 20-22-9
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook


Spanner Wrench 4

Hold the hydraulic cylinder over a drain pan and move


2
the rod in and out slowly to remove the fluid from the
1
cylinder.

Put the base end of the cylinder in a vise.


5
Use a spanner wrench to loosen the head [Figure 20-22- 3
6].

Figure 20-22-7 N-20611

2
4 3 1 Remove the wiper seal (Item 1), and rod seal (Item 2),
the back up washer (Item 3), the thin O-ring (Item 4), and
the thick O-ring (Item 5) [Figure 20-22-9] from the head.

P16294

Remove the head and rod assembly from the cylinder


[Figure 20-22-7]. Put the rod end in a vise.

Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-22-7] from the rod.

T300 Bobcat Loader


20-22-4 Service Manual
CYLINDER (POWER BOB-TACH) (CONT'D) Figure 20-22-11

Assembly
3 1
2
Figure 20-22-10

P16295

Piston: Install the O-ring (Item 1) and seal (Item 2) on the


P7424 piston (Item 3) [Figure 20-22-11].

NOTE: The piston center hole (Item 4) [Figure 20-22-


Use the following tools to assembly the cylinder: 11] has a bevel on one end. The bevel goes
toward the rod.
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool Figure 20-22-12
Piston Ring Compressor
Spanner Wrench

Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other


damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during


installation.

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612

Allow the seal to stretch for 30 seconds before installing it


on the piston. Install the rod seal on the rod seal tool [Figure 20-22-12].

NOTE: During installation the O-ring side of the seal


must be toward the inside of the cylinder.

T300 Bobcat Loader


20-22-5 Service Manual
CYLINDER (POWER BOB-TACH) (CONT'D) Figure 20-22-15

Assembly (Cont'd)

Figure 20-22-13

2
3

P7422

Install the thin O-ring (Item 1) [Figure 20-22-15].


N-20613
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-22-15] into the groove on the head.
Rotate the handles to collapse the rod seal [Figure 20-
22-13]. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the seal kit.
Figure 20-22-14
Figure 20-22-16

3
2 4
1

P7425
P16294

Install the rod seal in the head [Figure 20-22-14].


Install the head (Item 1), and spacer (Item 2) [Figure 20-
Install the wiper seal with the wiper toward the outside of 22-16].
the head.
Install the piston (Item 3) [Figure 20-22-16].

Lift Cylinder: Grease the piston where the nut contacts


the piston. do not get grease on the threads. Install the
new nut (Item 4) [Figure 20-22-16].

Tighten the nut to 90 ft.-lb. (122 N•m) torque.

T300 Bobcat Loader


20-22-6 Service Manual
CYLINDER (POWER BOB-TACH) (CONT'D)

Assembly (Cont'd)

Figure 20-22-17

P16293

Put the base end of the hydraulic cylinder in a vise.

Tighten the head using a spanner wrench [Figure 20-22-


17].

T300 Bobcat Loader


20-22-7 Service Manual
T300 Bobcat Loader
20-22-8 Service Manual
MAIN RELIEF VALVE Figure 20-30-1

Checking Main Relief


2 1

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

WARNING P-37687

When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-30-1] of the
steering levers must be in neutral and the parking hydraulic tester to the bottom (female) quick coupler on
brake engaged. Failure to do so can cause injury or the loader.
death.
W-2006-0284
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.

WARNING Figure 20-30-2

Put jackstands under the front axles and rear corners


of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

The tools listed will be needed to do the following


procedure:
1
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit

Turn the key switch to the OFF position. N-18409

NOTE: This procedure is for standard loaders,


loaders equipped with ACS option and Start the engine and run at low idle.
loaders equipped with SJC option. The main
relief valve is located in the same place on all • Press the AUXILIARY HYDRAULICS Button (Item 1)
of the loaders. [Figure 20-30-2] twice and the light beside Maximum
Flow comes on.
To release the hydraulic pressure at the front auxiliary
quick couplers push the couplers into the coupler block
and hold for three seconds.

Lift and block the loader. (See Procedure on Page 10-10-


1.)

T300 Bobcat Loader


20-30-1 Service Manual
MAIN RELIEF VALVE (CONT’D) Turn the restrictor control, on the tester, until the main
relief valve opens. Check the relief pressure.
Checking Main Relief (Cont’d)
If the relief pressure is not correct, stop the engine and
Figure 20-30-3 adjust the main relief valve.
Right
Steering
Lever
Control

1
P-31833

Figure 20-30-4

SJC Option Only

Right
Steering
1 Lever
Control

P-26697

• Push the front switch (Item 1) [Figure 20-30-3] &


[Figure 20-30-4] to give the front quick couplers a
constant flow of fluid.

• To release from continuous operation, press the front


switch (Item 1) [Figure 20-30-3] & [Figure 20-30-4] a
second time.

Watch the flow meter on the hydraulic tester to make


sure the flow is correct. Increase the engine speed to full
RPM.

Refer to Specifications, (Contents Page, SPEC-01) for


both flow and pressure specifications of the hydraulic
system.

Check the free flow specification.

T300 Bobcat Loader


20-30-2 Service Manual
MAIN RELIEF VALVE (CONT’D)

Adjustment

NOTE: This procedure is for standard loaders,


loaders equipped with ACS option and
loaders equipped with SJC option. The main
relief valve is located in the same place on all
of the loaders.

Figure 20-30-5

1
2

P-37690

If the pressure is not correct, adjust the main relief valve.


Loosen the lock nut (Item 1) [Figure 20-30-5].

Turn the adjusting screw (Item 2) [Figure 20-30-5] in or


out until the pressure is correct. Turning screw in will
increase pressure.

NOTE: If the correct pressure can not be reached,


replace the main relief valve. Check the
pressure setting of the new relief valve.

T300 Bobcat Loader


20-30-3 Service Manual
MAIN RELIEF VALVE (CONT’D) Figure 20-30-7

Removal and Installation

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-37689
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the O-rings and back-up washers from the main
Clean the area around the control valve. relief valve [Figure 20-30-7].

NOTE: This procedure is for standard loaders, Clean the main relief valve in clean solvent. Use air
loaders equipped with ACS option and pressure to dry the valve.
loaders equipped with SJC option. The main
relief valve is located in the same place on all Install new O-rings and back-up washers. Install the main
of the loaders. relief valve and tighten [Figure 20-30-7].

Figure 20-30-6 Installation: Tighten the main relief valve to 35-40 ft.-lb.
(47-54 N•m) torque.

Check the pressure again. (See Checking Main Relief on


Page 20-30-1.)

P-37690

NOTE: The right side motor cover if removed may


provide better access to the main relief valve
on some machines.

The main relief valve (Item 1) [Figure 20-30-6] is located


at the lower front of the control valve below the lift and tilt
spool connections.

Loosen and remove the main relief valve (Item 1) [Figure


20-30-6].

T300 Bobcat Loader


20-30-4 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-2
(FOOT CONTROL)

Identification

Figure 20-40-1

P-37098

1 Raise the lift arms and install an approved lift arm support
device.
N-18695
Stop the engine. Raise the seat bar.
The hydraulic control valve (2 piece casting) (foot control) Raise the operator cab. (See Raising The Operator Cab
has a removable BICS™ section (Item 1) [Figure 20-40- on Page 10-30-1.)
1].
Drain the hydraulic reservoir. (See Replacing Hydraulic
The BICS™ section and main control valve are in two Fluid And Case Drain Filters on Page 10-120-3.)
seperate castings.
Remove the control panel. (See Removal And Installation
For identification of the hydraulic control valve (1 piece on Page 50-100-1.)
casting) (foot control), (See Identification Chart on Page
20-43-5.). Clean area around control valve.
Removal And Installation Open rear door.

The fixed end main valve hose assembly (Item 1) [Figure


20-40-2] is connected to a fixed end fitting on the control
valve. The hose is routed to the upright where the hose is
connected to a fitting that feeds the base end of both lift
cylinders. The hose can only be removed by first
removing it from the tee fitting located at the rear of the
loader.

Cap and plug the hoses and fittings.

Remove the lift arm by-pass valve. (See Removal And


WARNING Installation on Page 20-50-1.)

Never work on a machine with the lift arms up unless


the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

T300 Bobcat Loader


20-40-1 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-5
(FOOT CONTROL) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-40-3

2
2
1

P-34124

Disconnect the harness connector (Item 1) [Figure 20-


40-5] from the BICS™ valve solenoid connector.
P-37099
Disconnect the harness connector (Item 2) [Figure 20-
40-5] from the auxiliary valve solenoid.
Disconnect the tubeline (Item 1) [Figure 20-40-3] that
goes from the control valve to the hydraulic cooler. Figure 20-40-6

Disconnect the charge pressure sender (Item 2) [Figure


20-40-3] from the control valve.

Figure 20-40-4
1
2
1

P-34125
1
Disconnect foot control linkage (Item 1) [Figure 20-40-6]
from the tilt spool on the control valve.
P-34123
Disconnect foot control linkage (Item 2) [Figure 20-40-6]
from the lift spool on the control valve.
Mark the wire connectors for proper installation.
Move the control linkages to allow clearance for the
Disconnect the three wire harness connector (Item 1) control valve removal.
[Figure 20-40-4] from auxiliary valve solenoid, and the
lift and tilt lock solenoids.

T300 Bobcat Loader


20-40-2 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-9
(FOOT CONTROL) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-40-7
1

P-34128

Remove the two control valve mount bracket mount bolts


(Item 1) [Figure 20-40-9].
P-34126
Figure 20-40-10

Loosen the fixed end main valve hose assembly (Item 1)


[Figure 20-40-7] from the control valve.

The hose can be removed from the control valve by


rotating the hose assembly.
1
Cap the hose and plug the fitting.

Figure 20-40-8
1

1
2 P-34129

At the right side motor cover access hose, remove the


two control valve mount bolts (Item 1) [Figure 20-40-10]
from the mounting plate.

Remove the control valve mount bracket from the loader.

P-34127

Install a chain hoist (Item 1) [Figure 20-40-8] to the


control valve, and support the control valve.

Remove the case drain hose (Item 2) [Figure 20-40-8]


from the control valve to the case drain filter.

Loosen all the tubeline fittings connected to the control


valve.

T300 Bobcat Loader


20-40-3 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-13
(FOOT CONTROL) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-40-11
1

2
P-34132

Disconnect the tilt tubeline (Item 1) [Figure 20-40-13]


from the control valve.
P-34130
Cap and plug the tubeline and fitting.

Disconnect the case drain hose (Item 1) [Figure 20-40- Figure 20-40-14
11] and cap the fitting and plug the hose.

Disconnect the two auxiliary tubelines (Item 2) [Figure


20-40-11] from the control valve.

Figure 20-40-12
1

P-34133

2 With the chain hoist lift the control valve up and clear of
the tubelines [Figure 20-40-14].

P-34131 Disconnect the hydraulic hose (Item 1) [Figure 20-40-14]


that comes from the back of the gear pump to the bottom
of the control valve.
Disconnect the tilt tubeline (Item 1) [Figure 20-40-12]
from the control valve. Remove the control valve from the loader.

Disconnect the lift tubeline (Item 2) [Figure 20-40-12]


from the control valve.

T300 Bobcat Loader


20-40-4 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-17
(FOOT CONTROL) (CONT’D)

BICS™ Valve, Removal And Installation

Figure 20-40-15

1 1
1
1

2
1
1
1
N-20035

1
Remove the four large O-rings (Item 1) and the small O-
ring (Item 2) from the top of the control valve [Figure 20-
N-20033 40-17].

Install the four large O-rings (Item 1) and the small O-ring
Remove the control valve. (See Removal And Installation (Item 2) on the top of the control valve [Figure 20-40-17].
on Page 20-40-1.)

To remove the BICS™ valve from the control valve,


loosen and remove the six mounting bolts (Item 1)
[Figure 20-40-15].

Figure 20-40-16

N-20034

Remove the BICS™ valve assembly from the top of the


control valve [Figure 20-40-16].

T300 Bobcat Loader


20-40-5 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) The chart below lists the correct torque specifications
(FOOT CONTROL) (CONT’D) and tightening sequence when reinstalling the BICS]
valve assembly to the control valve. Thoroughly clean
BICS™ Valve, Removal And Installation (Cont’d) and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.
Figure 20-40-18
Step Torque Sequence
1 110-130 in.-lb.
3 (12,4-14,7 N•m)
6
2 190-210 in.-lb.
1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
1 3 190-210 in.-lb.
2 (21,5-23,7 N•m)
5

*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for


4 every bolt or repeat step 3.

N-20033

Install the six mounting bolts [Figure 20-40-18].

T300 Bobcat Loader


20-40-6 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-21
(FOOT CONTROL) (CONT’D)

BICS™ Valve, Lift Arm By-Pass Orifice Removal And


Installation

Figure 20-40-19

1
N-18685

Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-20] & [Figure 20-40-
21].
N-20040
Orifice size is 0.078 inch.

Remove the fitting (Item 1) [Figure 20-40-19] from the Reverse the removal procedure to install the lift arm by-
valve. pass orifice.

Figure 20-40-20

N-20041

T300 Bobcat Loader


20-40-7 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-24
(FOOT CONTROL) (CONT’D)

BICS™ Valve, Check Valve Removal And Installation

Figure 20-40-22
1

P-8956
1

Clean and inspect the screen (Item 1) [Figure 20-40-24]


on the end of the valve.
N-20037

Remove the check valve (Item 1) [Figure 20-40-22].

Installation: Tighten the valve to 20 ft.-labs. (27 N•m)


torque.

Figure 20-40-23

N-18684

Remove the O-rings (Item 1) and back-up ring (Item 2)


from the check valve [Figure 20-40-23].

Install new O-rings and back-up ring on the check valve.

The check valve has a rating of 5-10 PSI.

T300 Bobcat Loader


20-40-8 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-27
(FOOT CONTROL) (CONT’D)

Backslide, Lock Valve Removal And Installation

Figure 20-40-25
1

1
1

N-20040

Remove the lock valves (Item 1) [Figure 20-40-25],


[Figure 20-40-26] & [Figure 20-40-27] from the BICS™
N-20033 valve.

Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m)


Figure 20-40-26 torque.

Figure 20-40-28

2
N-20039
2
2
N-18690

Remove the O-rings (Item 1) and back-up rings (Item 2)


from both the tilt and lift lock valves [Figure 20-40-28].

Install new O-rings (Item 1) and back-up rings (Item 2)


on the tilt and lift lock valves [Figure 20-40-28].

Reverse the removal procedure to install the lock valve.

T300 Bobcat Loader


20-40-9 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-31
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Solenoid Removal And Installation


1
Figure 20-40-29

N-20038

Remove the solenoid stem (Item 1) [Figure 20-40-31].

N-20037 Installation: Tighten the solenoid stem to 20 ft.-lb. (27


N•m) torque.

Remove the mounting nut (Item 1) [Figure 20-40-29] Figure 20-40-32


from the solenoid cartridge.

Installation: Tighten the mounting nut to 53 in.-lb. (6


N•m) torque.
3
Remove the solenoid (Item 2) [Figure 20-40-29]. 2

NOTE: The solenoid resistance is (8-10 ohms).

Figure 20-40-30

1
1

1 N-18694

Remove the O-rings (Item 1) and back-up washers (Item


2) on the stem [Figure 20-40-32].

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and replace any part showing
excessive wear.
N-18693A
NOTE: The screen (Item 3) [Figure 20-40-32] may be
cleaned with solvent. If it is torn or worn
Remove the O-rings (Item 1) [Figure 20-40-30] from replace the solenoid stem.
both ends of the solenoid.
Use only new O-rings and apply oil to all O-rings and
back-up washers before installation.

Install new O-rings and new back-up washers on the


solenoid stem.

T300 Bobcat Loader


20-40-10 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Solenoid Testing

Figure 20-40-33

P9175

Use a test meter to measure coil resistance [Figure 20-


40-33]. Coil wires do not have polarity. Correct resistance
for the auxiliary pressure relief (small) coil is 7-10 ohm
and the other coils 5-8 ohms.

Replace the test meter with 12 volt power. You can see
and hear the spool shift.

T300 Bobcat Loader


20-40-11 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-34
(FOOT CONTROL) (CONT'D)

Identification Chart H2 H1

Item T300 Loader


A1 Lift Cylinder Base End/Restrictor H3
A2 Tilt Cylinder Base End
C4
A3 Auxiliary Hydraulics
B3 A3
B1 Lift Cylinder Rod End G3 D3
C3
B2 Tilt Cylinder Rod End
G2 B2 A2 E2 D2
B3 Auxiliary Hydraulics
F2 C2
C1 Load Check Valve/Lift Function G1 E1
B1 A1
C2 Load Check Valve/Tilt Function C1
F1
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow D1
D1 Lift Spool Detent
MR
D2 Tilt Spool Centering Spring TS-1971

D3 Auxiliary Spool/Centering Springs


E1 Port Relief Valve - 4000 PSI
E2 Anti-Cavitation/Port Relief Valve - 3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve - 4000 PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) - 3500 PSI
H3 Auxiliary Electric Solenoid
MR Main Relief Valve - 3300 PSI

T300 Bobcat Loader


20-40-12 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-36
(FOOT CONTROL) (CONT'D)

Load Check Valve


2
Figure 20-40-35

1
1 1

1 1

N-18698
2

Loosen the load check plugs (Item 1) [Figure 20-40-36]


from the lift and tilt sections of the control valve.
N-20035
Installation: Always use new O-ring. tighten the plug to
35-40 ft.-lb. (47-54 N•m) torque.
Remove the BICS valve assembly from the control valve.
(See BICS™ Valve, Removal And Installation on Page Figure 20-40-37
20-40-5.)

Remove the four large O-rings (Item 1) and small O-ring


(Item 2) [Figure 20-40-35]. Always replace these O-rings
before installing the BICS valve assembly.

3
IMPORTANT 1

When repairing hydrostatic and hydraulic systems,


clean the work area before disassembly and keep all 2
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
N-20077
damage the system.
I-2003-0888

Remove the load check plugs (Item 1) [Figure 20-40-37].


Mark each valve section, spool and related parts so that
they will be returned to its original valve section during Remove the spring (Item 2) and poppet (Item 3) [Figure
assembly. 20-40-37].

Use bolts to fasten the control valve to a work bench for NOTE: Both load checks poppets, plugs and springs
easier disassembly and assembly procedures. are the same for the lift and tilt.

Loosen the load check plug (Item 2) [Figure 20-40-36]


from the auxilliary section of the control valve.

T300 Bobcat Loader


20-40-13 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-40
(FOOT CONTROL) (CONT'D)
2 3
4
Load Check Valve (Cont’d) 5

Figure 20-40-38
1
B-6764

1. Relief Valve
2. O-ring
3. Sleeve
4. Glide Ring
5. O-ring

CD-15092

1 Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-40-40].
N-20078
Installation: Always use new O-rings. sleeve, and glide
ring. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.
The auxiliary section uses a load check poppet with an
orifice (Item 1) [Figure 20-40-38]. Port Relief Valve, Tilt Spool

NOTE: For correct port locations and valve Figure 20-40-41


component (See Identification Chart on Page
20-40-12.)

Main Relief Valve

Figure 20-40-39

N-20043

Remove the port relief valve (Item 1) [Figure 20-40-41]


1 from the control valve tilt section.

N-20039

Loosen and remove the main relief valve (Item 1) [Figure


20-40-39].

T300 Bobcat Loader


20-40-14 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-44
(FOOT CONTROL) (CONT'D)
4
Port Relief Valve, Tilt Spool (Cont’d)
3
Figure 20-40-42
2
4 1
3

2 1. O-ring
1 2. Back-up Washer
3. O-ring
4. Relief Valve

1. O-ring N-18844
2. Back-up Washer
3. O-ring
4. Relief Valve Remove the O-rings and back-up washer from the port
relief valve [Figure 20-40-44].
N-18844
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.
Remove the O-rings and back-up washer from the port
relief valve [Figure 20-40-42]. Anti-Cavitation Valve/Port Relief Valve, Tilt Spool

Installation: Always use new O-rings and back-up Figure 20-40-45


washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

Port Relief Valve, Lift Spool

Figure 20-40-43 1

1
N-20042

Remove the anti-cavitation/port relief valve (Item 1)


[Figure 20-40-45] from the control valve tilt section.
N-20040

Remove the port relief valve (Item 1) [Figure 20-40-43]


from the control valve lift section.

T300 Bobcat Loader


20-40-15 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-48
(FOOT CONTROL) (CONT'D)
1 2 3 4
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool
(Cont’d)

Figure 20-40-46 E-1509a

1. Anti-Cavitation Valve
2. O-ring
3. Back-up Washer
1 4. O-ring

N-18839

Remove the O-rings and back-up washer from the anti-


cavitation valve [Figure 20-40-48].

N-18843 Rubber Boot

Figure 20-40-49
Remove the O-rings (Item 1) [Figure 20-40-46] from the
anti-cavitation/port relief valve.

Installation: Always use new O-rings and back-up


washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

Anti-Cavitation Valve, Lift Spool 1

Figure 20-40-47

N-20043

Remove the two screws (Item 1) [Figure 20-40-49] on


the rubber boot retainer.
1
Installation: Tighten the screws to 90-100 in.-lb. (10,2-
11,3 N•m) torque.

N-20043

Remove the lift lock solenoid (Item 1) [Figure 20-40-47].

Remove the anti-cavitation valve (Item 2) [Figure 20-40-


47] from the control valve lift section.

T300 Bobcat Loader


20-40-16 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-52
(FOOT CONTROL) (CONT'D)

Rubber Boot (Cont’d)


1
Figure 20-40-50

2
2 1
2
2
1
1
N-20021

Remove the lock solenoids (Item 1) [Figure 20-40-51] &


[Figure 20-40-52] from the lift and tilt lock block.
N-20020
Remove the rubber Boot (Item 2) [Figure 20-40-51] &
[Figure 20-40-52]. (See Rubber Boot on Page 20-40-
Remove the rubber boot (Item 1) and retainer (Item 2) 16.)
[Figure 20-40-50].
Figure 20-40-53
Lift And Tilt Lock Block

Figure 20-40-51

N-20022
2

N-20043 Remove the lift and tilt lock block [Figure 20-40-53].

NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)

T300 Bobcat Loader


20-40-17 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-56
(FOOT CONTROL) (CONT'D)

Lift Spool And Detent Removal

Figure 20-40-54

N-20040
1

Remove the end cap (Item 1) [Figure 20-40-56].

N-20022 Figure 20-40-57

The tool listed will be needed to do the following


procedure:

MEL1278 - Detent Tool


MEL1285 - Detent Spring Tool
1
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
54] from the control valve. (See Lift And Tilt Lock Block
on Page 20-40-17.)
2
Figure 20-40-55

N-18971

Use a screwdriver to remove the snap ring (Item 1)


[Figure 20-40-57].
2
1 Remove the washer (Item 2) [Figure 20-40-57].

N-20023

Remove the bushing (Item 1) and O-ring (Item 2) from


the lift spool [Figure 20-40-55].

T300 Bobcat Loader


20-40-18 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-60
(FOOT CONTROL) (CONT'D)

Lift Spool And Detent Removal (Cont'd)

Figure 20-40-58

2 1

2 N-18974

1 Remove the detent sleeve (Item 1), detent balls (Item 2)


and spring (Item 3) [Figure 20-40-60].
N-18972
Figure 20-40-61

Remove the screws (Item 1) [Figure 20-40-58] from the


detent bonnet.

Remove the detent bonnet (Item 2) [Figure 20-40-58].

IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and 1
assembly.
I-2012-0284
N-18975

Figure 20-40-59
Remove the spool assembly and seal (Item 1) [Figure
20-40-61] from the control valve.

N-18973

Put a rag around the detent assembly [Figure 20-40-59].


This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.

T300 Bobcat Loader


20-40-19 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-64
(FOOT CONTROL) (CONT'D)

Lift Spool And Detent Disassembly 2

Figure 20-40-62
3 1

N-18915
1

Install the spring tool (Item 1) [Figure 20-40-64] over the


centering spring.
N-18930
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-64] from the centering
Remove the spool seal (Item 1) [Figure 20-40-62] from spring, as it is under spring pressure.
the linkage end of the valve.
NOTE: The centering spring (Item 3) [Figure 20-40-64]
Figure 20-40-63 is orange on all large frame loaders.

Figure 20-40-65

P-8988
1
2

N-18916
Clamp the linkage end of the spool in a vise [Figure 20-
40-63].
Put a rag around the detent assembly [Figure 20-40-65].
This will prevent the detent balls and spring from being
lost when the detent adapter is removed.

Remove the detent adapter with an allen wrench.

Remove the back-up washer (Item 1) and spool seal


(Item 2) [Figure 20-40-65].

T300 Bobcat Loader


20-40-20 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-68
(FOOT CONTROL) (CONT'D)
1
Lift Spool And Detent Disassembly (Cont'd) 2
3
Figure 20-40-66
4

N-18919A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-68].
N-19004
Figure 20-40-69

Remove the detent adapter (Item 1) [Figure 20-40-66]


from the spring assembly.

Figure 20-40-67

N-18918

Remove the stud from the end of the spool [Figure 20-
40-69].
N-19009

Remove spring tool (Item 1) [Figure 20-40-67] from the


spring assembly.

T300 Bobcat Loader


20-40-21 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Lift Spool And Detent Disassembly (Cont'd)

Figure 20-40-70

N-18920

Removal of the plastic plug:

Make a center point in the plug using a 1/16 inch drill.

Drill a hole all the way through the plug using a 7/64 inch
tap drill

Turn a 6-32 tap (Item 1) [Figure 20-40-70] into the plug.


Pull the tap and plug out of the spool. Be careful, do not
break the tap.

Clean all the debris from inside the spool bore.

NOTE: DO NOT USE LOCTITE ON THE STUD


THREADS.

T300 Bobcat Loader


20-40-22 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-73
(FOOT CONTROL) (CONT'D)

Lift Spool And Detent Assembly O-ring

Figure 20-40-71

2
Plastic
1 Plug

0.60 inch
(15,2 mm)

B-14712

Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
N-18961 20-40-73].

Figure 20-40-74
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-71].

Figure 20-40-72

N-18967

Clamp the collar (Item 1) [Figure 20-40-74] in a vice.


N-18963

Install the plastic plug and O-ring in the spool [Figure 20-
40-72].

T300 Bobcat Loader


20-40-23 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-77
(FOOT CONTROL) (CONT'D)

Lift Spool And Detent Assembly (Cont’d)

Figure 20-40-75

1
2

N-19004
1
3
2 Install the spring tool (Item 1) [Figure 20-40-77] over the
washer, spring, collar and detent adapter.
N-18958
Figure 20-40-78

Apply grease on all the detent component surfaces


before assembly [Figure 20-40-75].

Install the spring (Item 1) [Figure 20-40-75] and detent


balls (Item 2) [Figure 20-40-75] into the adapter (Item 3)
[Figure 20-40-75] and compress with the detent pliers 2
(Item 1) [Figure 20-40-76].

Figure 20-40-76
1

N-18917

Install the spool seal (Item 1) and back-up washer (Item


2) [Figure 20-40-78].

N-18968

Install the detent adapter to the collar [Figure 20-40-76].

NOTE: The collar and the detent adapter are held


together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

T300 Bobcat Loader


20-40-24 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-81
(FOOT CONTROL) (CONT'D)

Lift Spool And Detent Assembly (Cont’d)

Figure 20-40-79

N-19007

Hold the detent balls in place with the detent pliers


[Figure 20-40-81].
N-19005
Figure 20-40-82

Install the spring assembly to the lift spool hand tight


[Figure 20-40-79].

Remove the spring tool.

Check the alignment of the detent adapter and the


washer.
1
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-79].

Tighten the adapter to 90-100 in.-lb. (10,2-11,3 N•m).

Figure 20-40-80
N-19008

Install the detent sleeve (Item 1) [Figure 20-40-82] to the


detent adapter.

CD-15051

Install the detent balls and spring [Figure 20-40-80].

T300 Bobcat Loader


20-40-25 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-85
(FOOT CONTROL) (CONT'D)

Lift Spool And Detent Assembly (Cont’d)

Figure 20-40-83

1
2

N-20040

1
Install the end cap (Item 1) [Figure 20-40-85].
2
N-18972

Install the lift spool assembly in the spool bore [Figure


20-40-83].

Install the detent bonnet (Item 1) [Figure 20-40-83].

Install the mounting screws (Item 2) [Figure 20-40-83].

Installation: Tighten the screws to 90-100 in.-lb. (10,2-


11,3 N•m) torque.

Figure 20-40-84

N-18971

Install the washer (Item 1) and snap ring (Item 2) [Figure


20-40-84].

T300 Bobcat Loader


20-40-26 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-88
(FOOT CONTROL) (CONT'D)

Lift Spool And Detent Installation

Figure 20-40-86

1 N-20022

Install the lift and tilt lock block (Item 1) [Figure 20-40-
88]. (See Lift And Tilt Lock Block on Page 20-40-17.)
N-18930

Install the spool seal (Item 1) [Figure 20-40-86] on the


linkage end of the valve.

Figure 20-40-87

1 2

N-18927

Install the bushing (Item 1) and O-ring (Item 2) on the


linkage end of the lift spool [Figure 20-40-87].

T300 Bobcat Loader


20-40-27 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-91
(FOOT CONTROL) (CONT'D)

Tilt Spool Removal And Installation

Figure 20-40-89
1

N-20042

1 Remove the screws (Item 1) [Figure 20-40-91] from the


end cap.
N-20022
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3
N•m) torque.
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
89] from the control valve. (See Lift And Tilt Lock Block Figure 20-40-92
on Page 20-40-17.)

Figure 20-40-90

1 2

N-18816

N-20024 Remove the spool, centering spring, back-up washer and


spool seal [Figure 20-40-92].

Remove the bushing (Item 1) [Figure 20-40-90] and O- Assembly: Always use a new spool seal.
ring (Item 2) [Figure 20-40-90] from the tilt spool.

T300 Bobcat Loader


20-40-28 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-95
(FOOT CONTROL) (CONT'D)
1
Tilt Spool Disassembly And Assembly 2
3
Figure 20-40-93
4

N-18944

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-95].
N-18942
Figure 20-40-96

Put the linkage end of the spool in the vice [Figure 20- 2
40-93].
1
Install the spool tool (Item 1) [Figure 20-40-93] over the
centering spring.

Figure 20-40-94

1
1

N-19098 N-18943

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-40-96].

Assembly: Always use a new spool seal.

N-19014

Remove the bolt (Item 1) [Figure 20-40-94] holding the


centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.

Remove spring tool from the spring assembly.

T300 Bobcat Loader


20-40-29 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-99
(FOOT CONTROL) (CONT'D)

Auxiliary Spool Removal And Installation

Figure 20-40-97

N-18989

1
Remove the spool (Item 1) [Figure 20-40-99].

N-20042 Assembly: Put grease on all the centering spring


component parts.

Remove the screws (Item 1) [Figure 20-40-97] from the Figure 20-40-100
end cap.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.

Figure 20-40-98

1
1

N-20043

Remove the lock solenoid (Item 1) [Figure 20-40-100]


from the tilt lock block.

N-18990

Remove the end cap, O-ring, springs and centering


spring retainer [Figure 20-40-98].

NOTE: If the centering spring retainer (Item 1) [Figure


20-40-98] must be replaced, replace the
retainer on the opposite end also.

Assembly: Always use a new spool seal.

T300 Bobcat Loader


20-40-30 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-103
(FOOT CONTROL) (CONT'D)

Auxiliary Spool Removal And Installation (Cont’d)

Figure 20-40-101

2
2
N-20075

Remove the centering spring retainer (Item 1) and


1 springs (Item 2) [Figure 20-40-103].
N-20073
Remove the spool (Item 3) [Figure 20-40-103].

Remove the screws (Item 1) from the auxiliary bleed Assembly: Put grease on all the centering spring
block (Item 2) [Figure 20-40-101]. component parts.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3 NOTE: If the centering spring retainer (Item 1) [Figure
N•m) torque. 20-40-103] must be replaced, replace the
retainer on the opposite end also.
Figure 20-40-102

N-20074

Remove the auxiliary bleed block (Item 1) [Figure 20-40-


102] and O-ring.

Assembly: Always use a new O-ring.

T300 Bobcat Loader


20-40-31 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Auxiliary Plug Removal And Installation

Figure 20-40-104

N-20031

Remove the plug (Item 1) [Figure 20-40-104] auxiliary


section of the control valve.

Figure 20-40-105

N-20076

Replace the O-rings (Item1) [Figure 20-40-105].

Check the orfice (Item 2) [Figure 20-40-105], to make


sure it is not pluged.

T300 Bobcat Loader


20-40-32 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-108
(FOOT CONTROL) (CONT'D)

Auxiliary Electric Solenoid Disassembly

Figure 20-40-106

N-20027

Remove the coil (Item 1) and end plate (Item 2) [Figure


1 20-40-108].
N-20025
Remove the solenoid stem (Item 3) [Figure 20-40-108].

Remove the nut (Item 1) [Figure 20-40-106] from both Installation: Tighten valve to 8-12 ft.-lb. (11-16 N•m)
solenoids. torque.

Installation: Tighten the nut to 8-12 ft.-lb. (11-16 N•m) Figure 20-40-109
torque.

Figure 20-40-107

1
N-18795
2

N-20026 Remove the O-rings (Item 1) [Figure 20-40-109] from


the solenoid stem.

Remove the end plate (Item 1) and housing (Item 2)


[Figure 20-40-107].

T300 Bobcat Loader


20-40-33 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-112
(FOOT CONTROL) (CONT'D)
Port Relief (Optional)
Port-Auxiliary Section Removal And Installation

Figure 20-40-110
1 2

1
1
N-18843

Remove the O-rings (Item 1) [Figure 20-40-111] &


[Figure 20-40-112] and back-up ring (Item 2) [Figure 20-
N-20031 40-111] & [Figure 20-40-112] from the plug or relief
valve.

Remove the plug (Item 1) [Figure 20-40-110] or optional Cleaning And Inspection
port relief valve from the control valve.
Clean all components with clean solvent and dry with
NOTE: Optional port relief (Item 1) [Figure 20-40-110] compressed air.
is 3500 PSI (24129 kPa).
Check the spools for wear or scratches.
Figure 20-40-111
Check that the spools are not loose in their bore.
Plug
Check that the centering springs are not broken.

2 Check that the load check valve seats are not worn.

Check the load check poppets for damage.

Check the rubber boots and retainers.

Replace the parts as needed.


1
Use new O-rings and back-up rings.

N-18800 Apply oil to all new O-rings and back-up rings before
installation.

T300 Bobcat Loader


20-40-34 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS)

Identification

Figure 20-41-1

N-18695

The hydraulic control valve (2 piece casting) (Advance


Control System) (ACS) has a removable BICS™ section
(Item 1) [Figure 20-41-1].

The BICS™ section and main control valve are in two


seperate castings.

For identification of the hydraulic control valve (1 piece


casting) (Advanced Control System) (ACS), (See
Removal And Installation on Page 20-44-2.)

T300 Bobcat Loader


20-41-1 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-3
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Actuator Removal And Installation (In Loader)

Raise the lift arms and install an approved lift arm support
device. (See Installing The Lift Arm Support Device on 1
Page 10-20-1.) 1

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm P-39425

support device can allow the lift arms or attachment


to fall and cause injury or death.
W-2059-0598
Remove the two actuator mount bolts (Item 1) [Figure
20-41-3] from the top actuator.

Stop the engine. Raise the seat bar. Installation: Tighten the bolts to 90-100 in.-lb. (10,2-11,3
N•m) torque.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)

Remove the Lift Arm By-Pass Valve. (See Removal And Figure 20-41-4
Installation on Page 20-50-1.)

Figure 20-41-2

1
1
P-39426

P-39424 Slide the actuator (Item 1) [Figure 20-41-4] away from


the control valve.

Disconnect the actuator wire connectors (Item 1) [Figure With a punch, remove the actuator pin (Item 2) [Figure
20-41-2] from the actuators. 20-41-4] from the actuator and spool.

Remove the upper actuator from the loader.

T300 Bobcat Loader


20-41-2 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Actuator Removal And Installation (In Loader)


(Cont’d)

Figure 20-41-5

1 1

P-39427

Remove the two actuator mount bolts (Item 1) [Figure


20-41-5] from the bottom actuator.

Installation: Tighten the bolts to 90-100 in.-lb. (10,2-11,3


N•m) torque

Figure 20-41-6

1
2

P-39428

Slide the actuator (Item 1) [Figure 20-41-6] away from


the control valve.

With a punch, remove the actuator pin (Item 2) [Figure


20-41-6] from the actuator and spool.

Remove the bottom actuator from the loader.

T300 Bobcat Loader


20-41-3 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-9
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Actuator Removal And Installation (Out Of Loader)

Figure 20-41-7

3
2

1 1
N-19114

2 1 Remove the actuator (Item 1), the O-ring (Item 2), the
spacer block (Item 3) and O-ring (Item 4) [Figure 20-41-
N-19112 9].

NOTE: There are two types of sealing designs used


Remove the two screws (Item 1) [Figure 20-41-7] on the on the actuators and the actuator mounts.
actuator retainer.
Figure 20-41-10
Installation: Tighten the bolt and nut to 90-100 in.-lb.
(10,2-11,3 N•m) torque.
EARLIER SEALING STYLE
Pull the actuator (Item 2) [Figure 20-41-7] away from the
control valve.

Figure 20-41-8

1
3

P-51830
1

The earlier style has the O-ring (Item 1) in the actuator


mount (Item 2). The actuator sealing face (Item 3)
[Figure 20-41-10] has a flat face and no O-ring.

N-19113

Use a drift pin and hammer to remove the actuator pin


(Item 1) [Figure 20-41-8] from the actuator and the lift or
tilt spool.

T300 Bobcat Loader


20-41-4 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Actuator Removal And Installation (Out Of Loader)


(Cont’d)

Figure 20-41-11

LATER SEALING STYLE

1
2
3
P-51831

The later style has the O-ring (Item 1) in the actuator


sealing face (Item 2). The actuator mount (Item 3)
[Figure 20-41-11] has no O-ring.

NOTE: The later style actuator can replace the earlier


style actuator as long as the actuator mount is
changed to the later style actuator mount.

T300 Bobcat Loader


20-41-5 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-12
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Removal And Installation

P-37098

WARNING
The fixed end main valve hose assembly (Item 1) [Figure
Never work on a machine with the lift arms up unless 20-41-12] is connected to a fixed end fitting on the
the lift arms are secured by an approved lift arm control valve. The hose is routed to the right side upright
support device. Failure to use an approved lift arm where the hose is connected to a tee fitting that feeds the
support device can allow the lift arms or attachment base end of both lift cylinders. The hose can only be
to fall and cause injury or death. removed by first removing it from the tee fitting located at
W-2059-0598 the rear of the loader.

Raise the lift arms and install an approved lift arm support Cap and plug the hose and fitting.
device.
Figure 20-41-13
Stop the engine. Raise the seat bar.

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Drain the hydraulic reservoir. (See Replacing Hydraulic


Fluid And Case Drain Filters on Page 10-120-3.) 1

Remove the control panel.(See Removal And Installation


on Page 50-100-1.)
2
Remove the Lift Arm By-Pass Valve. (See Removal And
Installation on Page 20-50-1.)

Remove the control valve actuators. (See Actuator P-39429


Removal And Installation (In Loader) on Page 20-41-2.)

Clean area around control valve. Mark the wire connectors for proper installation.

Open rear door. Disconnect the electrical connector (Item 1) [Figure 20-
41-13] from the auxiliary spool solenoid.

Disconnect the electrical connector (Item 2) [Figure 20-


41-13] from the BICS valve solenoid.

T300 Bobcat Loader


20-41-6 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-16
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Removal And Installation (Cont'd)

Figure 20-41-14

P-34126

Loosen the fixed end main valve hose assembly (Item 1)


[Figure 20-41-16] from the control valve.
P-39430
The hose can be removed from the control valve by
rotating the hose assembly.
Disconnect the electrical connector (Item 1) [Figure 20-
41-14] from the auxiliary spool solenoid. Cap the hose and plug the fitting.

Figure 20-41-15 Figure 20-41-17

2 1
1

P-37099
P-34127

Disconnect the tubeline (Item 1) [Figure 20-41-15] that Install a chain hoist (Item 1) [Figure 20-41-17] to the
goes from the control valve to the hydraulic cooler. control valve, and support the control valve.

Disconnect the charge pressure sender (Item 2) [Figure Loosen all the tubeline fittings connected to the control
20-41-15] from the control valve. valve.

Cap and plug the tubelines and fittings.

T300 Bobcat Loader


20-41-7 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-20
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)
1
Removal And Installation (Cont'd)

Figure 20-41-18

1
1

P-34129

Remove the two control valve mount bolts (Item 1)


[Figure 20-41-20] from the mounting plate, at the back
P-43930 side of the control valve.

Remove the control valve mount bracket from the loader.


Disconnect the hydraulic hose (Item 1) [Figure 20-41-18]
that comes from the back of the gear pump to the Figure 20-41-21
tubeline at the top of the control valve.

Figure 20-41-19
2
1 1

P-34130

P-43931 Disconnect the case drain hose (Item 1) [Figure 20-41-


21] and cap the fitting and plug the hose.

Remove the two control valve mount bracket mounting Disconnect the two tubelines (Item 2) [Figure 20-41-21]
bolts (Item 1) [Figure 20-41-19]. from the auxiliary section of the control valve.

Remove the tubeline clamp mount bolt (Item 2) [Figure Cap the fittings and plug the tubelines.
20-41-19].

T300 Bobcat Loader


20-41-8 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Removal And Installation (Cont'd)

Figure 20-41-22

P-34131

Disconnect the tilt tubeline (Item 1) [Figure 20-41-22]


from the control valve.

Disconnect the lift tubeline (Item 2) [Figure 20-41-22]


from the control valve.

Figure 20-41-23

P-34132

Disconnect the tilt tubeline (Item 1) [Figure 20-41-23] at


the tee fitting.

Cap and plug the tubeline and fitting.

Remove the control valve from the loader.

T300 Bobcat Loader


20-41-9 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-26
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

BICS™ Valve, Removal And Installation

Figure 20-41-24

1 1
1
1

2
1 1

1
N-20035
1

Remove the four large O-rings (Item 1) and the small O-


ring (Item 2) from the top of the control valve [Figure 20-
N-20033 41-26].

Installation: Install the four large O-rings (Item 1) and


To remove the BICS™ valve from the control valve, the small O-ring (Item 2) on the top of the control valve
loosen and remove the six mounting bolts (Item 1) [Figure 20-41-26].
[Figure 20-41-24].

Figure 20-41-25

N-20034

Remove the BICS™ valve assembly from the top of the


control valve [Figure 20-41-25].

T300 Bobcat Loader


20-41-10 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-28
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

BICS™ Valve, Removal And Installation (Cont'd)

Figure 20-41-27 1 1

1 1
6
3

1
1 2 1

5 N-23644
4

To remove the BICS™ valve from the control valve,


loosen and remove the six mounting bolts (Item 1)
N-20033 [Figure 20-41-28].

Figure 20-41-29
Install the six mounting bolts [Figure 20-41-27].

The chart below lists the correct torque specifications


and tightening sequence when reinstalling the BICS™
valve assembly to the control valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.

Step Torque Sequence


1 110-130 in.-lb.
(12,4-14,7 N•m)
2 190-210 in.-lb.
1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
3* 190-210 in. lb.
(21,5-23,7 N•m) N-23645

*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for Remove the BICS™ valve assembly from the top of the
every bolt or repeat step 3. control valve [Figure 20-41-29].

T300 Bobcat Loader


20-41-11 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) The chart below lists the correct torque specifications
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D) and tightening sequence when reinstalling the BICS™
valve assembly to the control valve. Thoroughly clean
BICS™ Valve, Removal And Installation (Cont’d) and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.
Figure 20-41-30
Step Torque Sequence
1 110-130 in.-lb.
(12,4-14,7 N•m)
2 190-210 in.-lb. 1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
3* 190-210 in. lb.
1 1
(21,5-23,7 N•m)

*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for


2 every bolt or repeat step 3.

N-23646

Remove the four large O-rings (Item 1) and the small O-


ring (Item 2) from the top of the control valve [Figure 20-
41-30].

Install the four large O-rings (Item 1) and the small O-ring
(Item 2) on the top of the control valve [Figure 20-41-30].

Figure 20-41-31

3 6

1 2

5
4

N-23644

Install the six mounting bolts [Figure 20-41-31].

T300 Bobcat Loader


20-41-12 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-34
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

BICS™ Valve, Lift Arm By-Pass Orifice Disassembly


And Assembly

Figure 20-41-32

1 N-18685

Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-41-33] & [Figure 20-41-
34].
N-20040
Orifice size is 0.078 inch.

Remove the fitting (Item 1) [Figure 20-41-32] from the Reverse the removal procedure to install the lift arm by-
valve. pass orifice.

Figure 20-41-33

N-20041

T300 Bobcat Loader


20-41-13 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-37
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

BICS™ Valve, Check Valve Disassembly And


Assembly
1
Figure 20-41-35

P-8956

1 Clean and inspect the screen (Item 1) [Figure 20-41-37]


on the end of the valve.

N-20037

Remove the check valve (Item 1) [Figure 20-41-35].

Installation: Tighten the valve to 20 ft.-lb. (27 N•m)


torque.

Figure 20-41-36

N-18684

Remove the O-rings (Item 1) and back-up ring (Item 2)


from the check valve [Figure 20-41-36].

Install new O-rings and back-up ring on the check valve.

The check valve has a rating of 5-10 PSI.

T300 Bobcat Loader


20-41-14 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-40
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

BICS™ Valve, Lock Valve Disassembly And


Assembly

Figure 20-41-38
1

1
N-20040

Remove the lock valves (Item 1) [Figure 20-41-38],


[Figure 20-41-39] & [Figure 20-41-40] from the BICS™
valve.
N-23644
Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m)
torque.
Figure 20-41-39

N-23647

T300 Bobcat Loader


20-41-15 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-43
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

BICS™ Valve, Lock Valve Disassembly And


Assembly (Cont’d) 1

Figure 20-41-41 1

N-18693A

2 Remove the O-rings (Item 1) [Figure 20-41-43] from


2 both ends of the solenoid.
2
N-18690 Figure 20-41-44

Remove the O-rings (Item 1) and back-up rings (Item 2)


from both the tilt and lift lock valves [Figure 20-41-41]. 1
Install new O-rings (Item 1) and back-up rings (Item 2) on
the tilt and lift lock valves [Figure 20-41-41].

Reverse the removal procedure to install the lock valve.

BICS™ Valve, Solenoid Disassembly And Assembly

Figure 20-41-42

1
N-20038

Remove the solenoid stem (Item 1) [Figure 20-41-44].

2 Installation: Tighten the solenoid stem to 20 ft.-lb. (27


N•m) torque.

N-20037

Remove the mounting nut (Item 1) [Figure 20-41-42]


from the solenoid cartridge.

Installation: Tighten the mounting nut to 53 in.-lb. (6


N•m) torque.

Remove the solenoid (Item 2) [Figure 20-41-42].

NOTE: The solenoid resistance is (8-10 ohms).

T300 Bobcat Loader


20-41-16 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) BICS™ Valve, Solenoid Testing
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)
Figure 20-41-46
BICS™ Valve, Solenoid Disassembly And Assembly
(Cont’d)

Figure 20-41-45

3
2

P9175
1
Use a test meter to measure coil resistance [Figure 20-
N-18694 41-46]. Coil wires do not have polarity. Correct resistance
for the auxiliary pressure relief (small) coil is 7-10 ohm
and the other coils 5-8 ohms.
Remove the O-rings (Item 1) and back-up washers (Item
2) on the stem [Figure 20-41-45]. Replace the test meter with 12 volt power. You can see
and hear the spool shift.
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and replace any part showing
excessive wear.

NOTE: The screen (Item 3) [Figure 20-41-45] may be


cleaned with solvent. If it is torn or worn
replace the solenoid stem.

Use only new O-rings and apply oil to all O-rings and
back-up washers before installation.

Install new O-rings and new back-up washers on the


solenoid stem.

T300 Bobcat Loader


20-41-17 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)
H2 H1
Identification Chart

ITEM T300 Loader ACS Hand Control H3


A1 Lift Cylinder Base End/Restrictor C4
A2 Tilt Cylinder Base End B3 A3 D3
G3
A3 Auxiliary Hydraulics C3 D2
B1 Lift Cylinder Rod End G2 B2 A2 E2
B2 Tilt Cylinder Rod End C2 D1
F2 G1 B1 A1 E1
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function F1 C1
MR
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function TS-2136
C4 Outlet Fluid Flow
D1 Lift Spool Centering Spring
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve – 4000 PSI
E2 Anti–Cavitation/Port Relief Valve – 3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve – 4000 PSI
G1 LIft Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) – 3500 PSI
H3 Auxiliary Electric Solenoid
MR Main Relief Valve – 3300 PSI

T300 Bobcat Loader


20-41-18 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Lift Base End Restrictor

Figure 20-41-47

N-21159

Remove the BICS™ valve assembly from the control


valve. (See BICS™ Valve, Removal And Installation on
Page 20-41-10.)

Remove the restrictor (Item 1) [Figure 20-41-47] from


the lift section base end port.

T300 Bobcat Loader


20-41-19 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-49
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Load Check Valve

Figure 20-41-48

1
1 1

1
1

N-19100

2 Loosen the load check valve plugs (Item 1) [Figure 20-


41-49].
N-19099
Installation: Always use new O-ring. Tighten the plug to
35-40 ft.-lb. (47-54 N•m) torque.
Remove the BICS™ valve assembly from the control
valve. (See BICS™ Valve, Removal And Installation on Figure 20-41-50
Page 20-41-10.)

Remove the four large O-rings (Item 1) and small O-ring


(Item 2) [Figure 20-41-48]. Always replace these O-rings
before installing the BICS™ valve assembly.

1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 3
tubelines and ports to keep dirt out. Dirt can quickly 2
N-19101
damage the system.
I-2003-0888

Remove the load check plugs (Item 1) [Figure 20-41-50].


Mark each valve section, spool and related parts so that
they will be returned to their original valve section during Remove the spring (Item 2) and poppet (Item 3) [Figure
assembly. 20-41-50].

Use bolts to fasten the control valve to a work bench for


easier disassembly and assembly procedures.

T300 Bobcat Loader


20-41-20 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Main Relief Valve
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)
Figure 20-41-52
Load Check Valve (Cont'd)

Figure 20-41-51

N-19034
2
N-19102 Loosen the main relief valve (Item 1) [Figure 20-41-52].

Figure 20-41-53
The auxiliary section (Item 1) uses an orifice load check
poppet (Item 2) [Figure 20-41-51].

N-19035

Remove the main relief valve (Item 1) [Figure 20-41-53].

T300 Bobcat Loader


20-41-21 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Main Relief Valve (Cont’d)

Figure 20-41-54

2 3
4 5

B-6764

1. Relief Valve
2. O-ring
3. Sleeve
4. Glide Ring
5. O-ring

CD-15092

Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-41-54].

Installation: Always use new O-rings, sleeve, and glide


ring. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

T300 Bobcat Loader


20-41-22 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-57
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Port Relief Valve

Figure 20-41-55

N-18981

Remove the port relief valve (Item 1) [Figure 20-41-57].

N-19000 Figure 20-41-58

4
Figure 20-41-56
3

2
1 1

1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve

N-18844

N-19034 Remove the O-rings and back-up washer from the port
relief valve [Figure 20-41-58].

Loosen the port relief valve (Item 1) [Figure 20-41-55] &


[Figure 20-41-56] (Port E1 or F2). (See Identification
Chart on Page 20-41-18.)

Installation: Always use new O-rings and back-up


washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

T300 Bobcat Loader


20-41-23 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-61
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Anti-Cavitation Valve/Port Relief Valve

Figure 20-41-59
1

N-18843

Remove the O-rings (Item 1) [Figure 20-41-61] from the


anti-cavitation/port relief valve.
N-19003

Loosen the anti-cavitation valve (Item 1) [Figure 20-41-


59].

Installation: Always use new O-rings and back-up


washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

Figure 20-41-60

N-18980

Remove the anti-cavitation/port relief valve (Item 1)


[Figure 20-41-60] from the control valve for the tilt
section.

T300 Bobcat Loader


20-41-24 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-64
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)
2
1 3 4
Anti-Cavitation Valve

Figure 20-41-62

1
E-1509A

1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring

N-18839

Remove the O-rings and back-up washer from the anti-


cavitation valve [Figure 20-41-64].
N-19034

Figure 20-41-63

1
N-19036

Remove the anti-cavitation valve (Item 1) [Figure 20-41-


62] & [Figure 20-41-63] from the control valve.

T300 Bobcat Loader


20-41-25 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-67
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Lift Spool Removal

Figure 20-41-65

N-19003

Remove the screws (Item 1) [Figure 20-41-67] from the


1 cap.
N-19112
Figure 20-41-68

Remove the actuator (Item 1) [Figure 20-41-65] from the


control valve.

Figure 20-41-66

2
N-18983

1
2
Remove the spool assembly (Item 1) [Figure 20-41-68]
and seal from the control valve.
N-19114

Remove the spacer (Item 1) and O-ring (Item 2) from the


lift spool [Figure 20-41-66].

T300 Bobcat Loader


20-41-26 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-71
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Lift Spool Removal And Installation

Figure 20-41-69
1

1
1

N-19003

Remove the screws (Item 1) [Figure 20-41-71] from the


end cap.
N-19112
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3
N•m) torque.
Remove the actuators (Item 1) [Figure 20-41-69] from
the control valve. Figure 20-41-72

Figure 20-41-70

2 1
2
1

N-18985

N-18940
Remove the spool assembly (Item 1) [Figure 20-41-72]
and seal from the control valve.
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-70] from the tilt spool. Assembly: Always use a new spool seal.

T300 Bobcat Loader


20-41-27 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-75
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)
2 1
Lift and Tilt Spool Disassembly And Assembly
3
Figure 20-41-73
4

N-18944A

NOTE: The center spring (Item 3) [Figure 20-41-75] is


orange on all large frame loaders.
N-18942
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-41-75].
Put the linkage end of the spool in the vise [Figure 20-
41-73]. Figure 20-41-76

Install the spool tool (Item 1) [Figure 20-41-73] over the 2


centering spring.
1
Figure 20-41-74

N-18930 N-18943

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-41-76].
N-19014
Assembly: Always use a new spool seal.

Remove the bolt (Item 1) [Figure 20-41-74] holding the


centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.

Remove spring tool from the spring assembly.

T300 Bobcat Loader


20-41-28 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-79
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Auxiliary Spool Removal And Installation

Figure 20-41-77 1

N-18988
1
Remove the spool (Item 1) [Figure 20-41-79].

N-19003 Assembly: Put grease on all the centering spring


component parts.

Remove the screws (Item 1) [Figure 20-41-77] from the


end cap (both sides).

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.

Figure 20-41-78

N-18987

Remove the end cap, O-ring, springs and washer (both


sides) [Figure 20-41-78].

Assembly: Always use a new spool seal.

T300 Bobcat Loader


20-41-29 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-82
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Auxiliary Electric Solenoid Disassembly

Figure 20-41-80

3 2

1 N-18992

1 Remove the coil (Item 1) and end plate (Item 2) [Figure


20-41-82].
N-18996
Remove the solenoid valve (Item 3) [Figure 20-41-82].

Remove the nut (Item 1) [Figure 20-41-80] from both Installation: Tighten valve to 8-12 ft.-lb. (11-16 N•m)
solenoids. torque.

Installation: Tighten the nut to 8-12 ft.-lb. (11-16 N•m) Figure 20-41-83
torque.

Figure 20-41-81

1
N-18795

N-18823 Remove the O-rings (Item 1) [Figure 20-41-83] from the


solenoid valves.

Remove the end plate (Item 1) and housing (Item 2)


[Figure 20-41-81].

T300 Bobcat Loader


20-41-30 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Cleaning And Inspection
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)
Clean all components with clean solvent and dry with
Port-Auxiliary Section Disassembly compressed air.

Figure 20-41-84 Check the spools for wear or scratches.

Check that the spools are not loose in their bore.

Check that the centering springs are not broken.

Check that the load check valve seats are not worn.

Check the load check poppets for damage.

Check the rubber boots and retainers


1
Replace the parts as needed.

Use new O-rings and back-up rings.


N-18996

Apply oil to all new O-rings and back-up rings before


installation.
Remove the plug (Item 1) [Figure 20-41-84] or optional
port relief valve from the control valve.

NOTE: Optional port relief (Item 1) [Figure 20-41-84]


is either 2500 PSI or 3000 PSI depending on
the option used.

Figure 20-41-85

Port Relief (Optional)

2
1

1
N-18843

Remove the O-rings (Item 1) [Figure 20-41-85] &


[Figure 20-41-85] and back-up ring (Item 2) [Figure 20-
41-85] & [Figure 20-41-85] from the plug.

T300 Bobcat Loader


20-41-31 Service Manual
T300 Bobcat Loader
20-41-32 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)

Identification

Figure 20-42-1

N-18695

The hydraulic control valve (2 piece casting) (Selectable


Joystick Control) (SJC) has a removable BICS™ section
(Item 1) [Figure 20-42-1].

The BICS™ section and main control valve are in two


seperate castings.

For identification of the hydraulic control valve (1 piece


casting) (Selectable Joystick Control) (SJC), (See
Identification Chart on Page 20-45-11.)

T300 Bobcat Loader


20-42-1 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-3
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Actuator Removal And Installation (In Loader)

Raise the lift arms and install an approved lift arm support
1
device. (See Installing The Lift Arm Support Device on 1
Page 10-20-1.)

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm P-39425
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove the two actuator mount bolts (Item 1) [Figure
W-2059-0598 20-42-3] from the top actuator.

Installation: Tighten the bolts to 90-100 in.-lb. (10,2-11,3


Stop the engine. Raise the seat bar. N•m) torque.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 20-42-4
Remove the Lift Arm By-Pass Valve. (See Removal And
Installation on Page 20-50-1.)

Figure 20-42-2

1 P-39426

Slide the actuator (Item 1) [Figure 20-42-4] away from


P-39424 the control valve.

With a punch, remove the actuator pin (Item 2) [Figure


Disconnect the actuator wire connectors (Item 1) [Figure 20-42-4] from the actuator and spool.
20-42-2] from the actuators.
Remove the upper actuator from the loader.

T300 Bobcat Loader


20-42-2 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Actuator Removal And Installation (In Loader)


(Cont’d)

Figure 20-42-5

1
1

P-39427

Remove the two actuator mount bolts (Item 1) [Figure


20-42-5] from the bottom actuator.

Installation: Tighten the bolts to 90-100 in.-lb. (10,2-11,3


N•m) torque

Figure 20-42-6

1
2

P-39428

Slide the actuator (Item 1) [Figure 20-42-6] away from


the control valve.

With a punch, remove the actuator pin (Item 2) [Figure


20-42-6] from the actuator and spool.

Remove the bottom actuator from the loader.

T300 Bobcat Loader


20-42-3 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-9
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Actuator Removal And Installation (Out Of Loader)

Figure 20-42-7

3
2

1
N-19114
1

Remove the actuator (Item 1), the O-ring (Item 2), the
2 1 spacer block (Item 3) and O-ring (Item 4) [Figure 20-42-
9].
N-19112

NOTE: There are two types of sealing designs used


on the actuators and the actuator mounts.
Remove the two screws (Item 1) [Figure 20-42-7] on the
actuator retainer.
Figure 20-42-10
Installation: Tighten the bolt and nut to 90-100 in.-lb.
(10,2-11,3 N•m) torque. EARLIER SEALING STYLE

Pull the actuator (Item 2) [Figure 20-42-7] away from the


control valve.

Figure 20-42-8

1
3

P-51830

1
The earlier style has the O-ring (Item 1) in the actuator
mount (Item 2). The actuator sealing face (Item 3)
[Figure 20-42-10] has a flat face and no O-ring.

N-19113

Use a drift pin and hammer to remove the actuator pin


(Item 1) [Figure 20-42-8] from the actuator and the lift or
tilt spool.

T300 Bobcat Loader


20-42-4 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Actuator Removal And Installation (Out Of Loader)


(Cont’d)

Figure 20-42-11

LATER SEALING STYLE

1
2
3
P-51831

The later style has the O-ring (Item 1) in the actuator


sealing face (Item 2). The actuator mount (Item 3)
[Figure 20-42-11] has no O-ring.

NOTE: The later style actuator can replace the earlier


style actuator as long as the actuator mount is
changed to the later style actuator mount.

T300 Bobcat Loader


20-42-5 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-12
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Removal And Installation

P-37098

WARNING The fixed end main valve hose assembly (Item 1) [Figure
20-42-12] is connected to a fixed end fitting on the
Never work on a machine with the lift arms up unless control valve. The hose is routed to the right side upright
the lift arms are secured by an approved lift arm where the hose is connected to a tee fitting that feeds the
support device. Failure to use an approved lift arm base end of both lift cylinders. The hose can only be
support device can allow the lift arms or attachment removed by first removing it from the tee fitting located at
to fall and cause injury or death. the rear of the loader.
W-2059-0598

Cap and plug the hose and fitting.


Raise the lift arms and install an approved lift arm support
device. Figure 20-42-13

Stop the engine. Raise the seat bar.

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Drain the hydraulic reservoir. (See Replacing Hydraulic 1


Fluid And Case Drain Filters on Page 10-120-3.)

Remove the control panel.(See Removal And Installation


on Page 50-100-1.) 2

Remove the Lift Arm By-Pass Valve. (See Removal And


Installation on Page 20-50-1.)
P-39429
Remove the control valve actuators. (See Actuator
Removal And Installation (In Loader) on Page 20-41-2.)
Mark the wire connectors for proper installation.
Clean area around control valve.
Disconnect the electrical connector (Item 1) [Figure 20-
Open rear door. 42-13] from the auxiliary spool solenoid.

Disconnect the electrical connector (Item 2) [Figure 20-


42-13] from the BICS valve solenoid.

T300 Bobcat Loader


20-42-6 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-16
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Removal And Installation (Cont'd)

Figure 20-42-14
1

P-34126

Loosen the fixed end main valve hose assembly (Item 1)


[Figure 20-42-16] from the control valve.

P-39430 The hose can be removed from the control valve by


rotating the hose assembly.
Disconnect the electrical connector (Item 1) [Figure 20-
Cap the hose and plug the fitting.
42-14] from the auxiliary spool solenoid.
Figure 20-42-17
Figure 20-42-15

1
2
1

P-34127
P-37099

Install a chain hoist (Item 1) [Figure 20-42-17] to the


Disconnect the tubeline (Item 1) [Figure 20-42-15] that
control valve, and support the control valve.
goes from the control valve to the hydraulic cooler.
Loosen all the tubeline fittings connected to the control
Disconnect the charge pressure sender (Item 2) [Figure
valve.
20-42-15] from the control valve.

Cap and plug the tubelines and fittings.

T300 Bobcat Loader


20-42-7 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-20
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)
1
Removal And Installation (Cont'd)

Figure 20-42-18

1 1

P-34129

Remove the two control valve mount bolts (Item 1)


[Figure 20-42-20] from the mounting plate, at the back
side of the control valve.
P-43930

Remove the control valve mount bracket from the loader.


Disconnect the hydraulic hose (Item 1) [Figure 20-42-18]
Figure 20-42-21
that comes from the back of the gear pump to the
tubeline at the top of the control valve.

Figure 20-42-19 2

1
1

P-34130

Disconnect the case drain hose (Item 1) [Figure 20-42-


P-43931 21] and cap the fitting and plug the hose.

Disconnect the two tubelines (Item 2) [Figure 20-42-21]


Remove the two control valve mount bracket mounting
from the auxiliary section of the control valve.
bolts (Item 1) [Figure 20-42-19].
Cap the fittings and plug the tubelines.
Remove the tubeline clamp mount bolt (Item 2) [Figure
20-42-19].

T300 Bobcat Loader


20-42-8 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Removal And Installation (Cont'd)

Figure 20-42-22

P-34131

Disconnect the tilt tubeline (Item 1) [Figure 20-42-22]


from the control valve.

Disconnect the lift tubeline (Item 2) [Figure 20-42-22]


from the control valve.

Figure 20-42-23

P-34132

Disconnect the tilt tubeline (Item 1) [Figure 20-42-23] at


the tee fitting.

Cap and plug the tubeline and fitting.

Remove the control valve from the loader.

T300 Bobcat Loader


20-42-9 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-26
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

BICS™ Valve, Removal And Installation

Figure 20-42-24
1 1

1
1
2

1 1

1 N-20035

1
Remove the four large O-rings (Item 1) and the small O-
ring (Item 2) from the top of the control valve [Figure 20-
42-26].
N-20033

Installation: Install the four large O-rings (Item 1) and


the small O-ring (Item 2) on the top of the control valve
To remove the BICS™ valve from the control valve,
[Figure 20-42-26].
loosen and remove the six mounting bolts (Item 1)
[Figure 20-42-24].

Figure 20-42-25

N-20034

Remove the BICS™ valve assembly from the top of the


control valve [Figure 20-42-25].

T300 Bobcat Loader


20-42-10 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-28
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

BICS™ Valve, Removal And Installation (Cont'd)


1 1
Figure 20-42-27

1 1
6
3
1
1
1 2

N-23644
5
4
To remove the BICS™ valve from the control valve,
loosen and remove the six mounting bolts (Item 1)
[Figure 20-42-28].
N-20033

Figure 20-42-29
Install the six mounting bolts [Figure 20-42-27].

The chart below lists the correct torque specifications


and tightening sequence when reinstalling the BICS™
valve assembly to the control valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.

Step Torque Sequence


1 110-130 in.-lb.
(12,4-14,7 N•m)
2 190-210 in.-lb.
1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
3* 190-210 in. lb. N-23645
(21,5-23,7 N•m)

Remove the BICS™ valve assembly from the top of the


*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for control valve [Figure 20-42-29].
every bolt or repeat step 3.

T300 Bobcat Loader


20-42-11 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) The chart below lists the correct torque specifications
(SELECTABLE JOYSTICK CONTROL) (SJC) and tightening sequence when reinstalling the BICS™
(CONT'D) valve assembly to the control valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
BICS™ Valve, Removal And Installation (Cont’d)
LOCTITE #242 or equivalent.
Figure 20-42-30 Step Torque Sequence
1 110-130 in.-lb.
(12,4-14,7 N•m)
2 190-210 in.-lb. 1, 2, 3, 4, 5 & 6
(21,5-23,7 N•m)
3* 190-210 in. lb.
1 (21,5-23,7 N•m)
1
*Torque must be 190-210 in.-lb. (21,5-23,7 N•m) for
every bolt or repeat step 3.
2

N-23646

Remove the four large O-rings (Item 1) and the small O-


ring (Item 2) from the top of the control valve [Figure 20-
42-30].

Install the four large O-rings (Item 1) and the small O-ring
(Item 2) on the top of the control valve [Figure 20-42-30].

Figure 20-42-31

3 6

1 2

5
4

N-23644

Install the six mounting bolts [Figure 20-42-31].

T300 Bobcat Loader


20-42-12 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-33
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

BICS™ Valve, Lift Arm By-Pass Orifice Disassembly


And Assembly

Figure 20-42-32

N-20041
1

Figure 20-42-34

N-20040

Remove the fitting (Item 1) [Figure 20-42-32] from the


valve.

N-18685

Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-42-33] & [Figure 20-42-
34].

Orifice size is 0.078 inch.

Reverse the removal procedure to install the lift arm by-


pass orifice.

T300 Bobcat Loader


20-42-13 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-37
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

BICS™ Valve, Check Valve Disassembly And


Assembly
1
Figure 20-42-35

P-8956

Clean and inspect the screen (Item 1) [Figure 20-42-37]


1
on the end of the valve.

N-20037

Remove the check valve (Item 1) [Figure 20-42-35].

Installation: Tighten the valve to 20 ft.-lb. (27 N•m)


torque.

Figure 20-42-36

N-18684

Remove the O-rings (Item 1) and back-up ring (Item 2)


from the check valve [Figure 20-42-36].

Install new O-rings and back-up ring on the check valve.

The check valve has a rating of 5-10 PSI.

T300 Bobcat Loader


20-42-14 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-40
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

BICS™ Valve, Lock Valve Disassembly And


Assembly

Figure 20-42-38 1

1
N-20040

Remove the lock valves (Item 1) [Figure 20-42-38],


[Figure 20-42-39] & [Figure 20-42-40] from the BICS™
valve.

N-23644 Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m)


torque.
Figure 20-42-39

N-23647

T300 Bobcat Loader


20-42-15 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-43
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

BICS™ Valve, Lock Valve Disassembly And


1
Assembly (Cont’d)
1
Figure 20-42-41

1
N-18693A

Remove the O-rings (Item 1) [Figure 20-42-43] from


2
both ends of the solenoid.
2
2 Figure 20-42-44
N-18690

Remove the O-rings (Item 1) and back-up rings (Item 2) 1


from both the tilt and lift lock valves [Figure 20-42-41].

Install new O-rings (Item 1) and back-up rings (Item 2) on


the tilt and lift lock valves [Figure 20-42-41].

Reverse the removal procedure to install the lock valve.

BICS™ Valve, Solenoid Disassembly And Assembly

Figure 20-42-42

1 N-20038

Remove the solenoid stem (Item 1) [Figure 20-42-44].

Installation: Tighten the solenoid stem to 20 ft.-lb. (27


2
N•m) torque.

N-20037

Remove the mounting nut (Item 1) [Figure 20-42-42]


from the solenoid cartridge.

Installation: Tighten the mounting nut to 53 in.-lb. (6


N•m) torque.

Remove the solenoid (Item 2) [Figure 20-42-42].

NOTE: The solenoid resistance is (8-10 ohms).

T300 Bobcat Loader


20-42-16 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) BICS™ Valve, Solenoid Testing
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D) Figure 20-42-46
BICS™ Valve, Solenoid Disassembly And Assembly
(Cont’d)

Figure 20-42-45

3
2

P9175

1
Use a test meter to measure coil resistance [Figure 20-
42-46]. Coil wires do not have polarity. Correct resistance
N-18694 for the auxiliary pressure relief (small) coil is 7-10 ohm
and the other coils 5-8 ohms.
Remove the O-rings (Item 1) and back-up washers (Item
Replace the test meter with 12 volt power. You can see
2) on the stem [Figure 20-42-45].
and hear the spool shift.
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and replace any part showing
excessive wear.

NOTE: The screen (Item 3) [Figure 20-42-45] may be


cleaned with solvent. If it is torn or worn
replace the solenoid stem.

Use only new O-rings and apply oil to all O-rings and
back-up washers before installation.

Install new O-rings and new back-up washers on the


solenoid stem.

T300 Bobcat Loader


20-42-17 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D) H2 H1

Identification Chart
H3
ITEM T300 Loader ACS Hand Control
C4
A1 Lift Cylinder Base End/Restrictor B3 A3
G3 D3
A2 Tilt Cylinder Base End
C3 D2
A3 Auxiliary Hydraulics B2 A2
G2 E2
B1 Lift Cylinder Rod End C2 D1
B2 Tilt Cylinder Rod End F2 G1 B1 A1 E1
B3 Auxiliary Hydraulics F1 C1
C1 Load Check Valve/Lift Function MR
C2 Load Check Valve/Tilt Function
TS-2136
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Centering Spring
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve – 4000 PSI
E2 Anti–Cavitation/Port Relief Valve – 3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve – 4000 PSI
G1 LIft Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) – 3500 PSI
H3 Auxiliary Electric Solenoid
MR Main Relief Valve – 3300 PSI

T300 Bobcat Loader


20-42-18 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Lift Base End Restrictor

Figure 20-42-47

N-21159

Remove the BICS™ valve assembly from the control


valve. (See BICS™ Valve, Removal And Installation on
Page 20-41-10.)

Remove the restrictor (Item 1) [Figure 20-42-47] from


the lift section base end port.

T300 Bobcat Loader


20-42-19 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-49
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Load Check Valve

Figure 20-42-48

1
1 1

1
1
N-19100

Loosen the load check valve plugs (Item 1) [Figure 20-


2 42-49].

N-19099 Installation: Always use new O-ring. Tighten the plug to


35-40 ft.-lb. (47-54 N•m) torque.
Remove the BICS™ valve assembly from the control
Figure 20-42-50
valve. (See BICS™ Valve, Removal And Installation on
Page 20-41-10.)

Remove the four large O-rings (Item 1) and small O-ring


(Item 2) [Figure 20-42-48]. Always replace these O-rings
before installing the BICS™ valve assembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 3
parts clean. Always use caps and plugs on hoses, 2
tubelines and ports to keep dirt out. Dirt can quickly N-19101

damage the system.


I-2003-0888
Remove the load check plugs (Item 1) [Figure 20-42-50].

Mark each valve section, spool and related parts so that Remove the spring (Item 2) and poppet (Item 3) [Figure
they will be returned to their original valve section during 20-42-50].
assembly.

Use bolts to fasten the control valve to a work bench for


easier disassembly and assembly procedures.

T300 Bobcat Loader


20-42-20 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Main Relief Valve
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D) Figure 20-42-52
Load Check Valve (Cont'd)

Figure 20-42-51

N-19034

2
Loosen the main relief valve (Item 1) [Figure 20-42-52].
N-19102

Figure 20-42-53
The auxiliary section (Item 1) uses an orifice load check
poppet (Item 2) [Figure 20-42-51].

N-19035

Remove the main relief valve (Item 1) [Figure 20-42-53].

T300 Bobcat Loader


20-42-21 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Main Relief Valve (Cont’d)

Figure 20-42-54

2 3
4 5

B-6764

1. Relief Valve
2. O-ring
3. Sleeve
4. Glide Ring
5. O-ring

CD-15092

Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-42-54].

Installation: Always use new O-rings, sleeve, and glide


ring. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

T300 Bobcat Loader


20-42-22 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-57
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Port Relief Valve

Figure 20-42-55

N-18981

Remove the port relief valve (Item 1) [Figure 20-42-57].

Figure 20-42-58
N-19000
4
Figure 20-42-56 3

2
1
1

1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve

N-18844

Remove the O-rings and back-up washer from the port


N-19034 relief valve [Figure 20-42-58].

Loosen the port relief valve (Item 1) [Figure 20-42-55] &


[Figure 20-42-56] (Port E1 or F2). (See Identification
Chart on Page 20-41-18.)

Installation: Always use new O-rings and back-up


washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

T300 Bobcat Loader


20-42-23 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-61
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Anti-Cavitation Valve/Port Relief Valve

Figure 20-42-59 1

N-18843

Remove the O-rings (Item 1) [Figure 20-42-61] from the


anti-cavitation/port relief valve.

N-19003

Loosen the anti-cavitation valve (Item 1) [Figure 20-42-


59].

Installation: Always use new O-rings and back-up


washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.

Figure 20-42-60

N-18980

Remove the anti-cavitation/port relief valve (Item 1)


[Figure 20-42-60] from the control valve for the tilt
section.

T300 Bobcat Loader


20-42-24 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-64
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D) 2
1 3 4
Anti-Cavitation Valve

Figure 20-42-62

1 E-1509A

1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring

N-18839

Remove the O-rings and back-up washer from the anti-


cavitation valve [Figure 20-42-64].

N-19034

Figure 20-42-63

1
N-19036

Remove the anti-cavitation valve (Item 1) [Figure 20-42-


62] & [Figure 20-42-63] from the control valve.

T300 Bobcat Loader


20-42-25 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-67
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Lift Spool Removal

Figure 20-42-65

N-19003

Remove the screws (Item 1) [Figure 20-42-67] from the


cap.
1
N-19112 Figure 20-42-68

Remove the actuator (Item 1) [Figure 20-42-65] from the


control valve.

Figure 20-42-66

2 N-18983

1
2 Remove the spool assembly (Item 1) [Figure 20-42-68]
and seal from the control valve.

N-19114

Remove the spacer (Item 1) and O-ring (Item 2) from the


lift spool [Figure 20-42-66].

T300 Bobcat Loader


20-42-26 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-71
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Lift Spool Removal And Installation

Figure 20-42-69 1

N-19003

Remove the screws (Item 1) [Figure 20-42-71] from the


end cap.

N-19112 Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.
Remove the actuators (Item 1) [Figure 20-42-69] from
Figure 20-42-72
the control valve.

Figure 20-42-70

2 1
2
1

N-18985

N-18940 Remove the spool assembly (Item 1) [Figure 20-42-72]


and seal from the control valve.
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
Assembly: Always use a new spool seal.
20-42-70] from the tilt spool.

T300 Bobcat Loader


20-42-27 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-75
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D) 1
2
Lift And Tilt Spool Disassembly And Assembly
3
Figure 20-42-73 4

N-18944A

NOTE: The center spring (Item 3) [Figure 20-42-75] is


orange on all large frame loaders.

N-18942 Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-42-75].
Put the linkage end of the spool in the vise [Figure 20-
Figure 20-42-76
42-73].
2
Install the spool tool (Item 1) [Figure 20-42-73] over the
centering spring. 1

Figure 20-42-74

1
1

N-18930 N-18943

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-42-76].

N-19014 Assembly: Always use a new spool seal.

Remove the bolt (Item 1) [Figure 20-42-74] holding the


centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.

Remove spring tool from the spring assembly.

T300 Bobcat Loader


20-42-28 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-79
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Auxiliary Spool Removal And Installation


1
Figure 20-42-77

N-18988

1
Remove the spool (Item 1) [Figure 20-42-79].

Assembly: Put grease on all the centering spring


N-19003 component parts.

Remove the screws (Item 1) [Figure 20-42-77] from the


end cap (both sides).

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.

Figure 20-42-78

N-18987

Remove the end cap, O-ring, springs and washer (both


sides) [Figure 20-42-78].

Assembly: Always use a new spool seal.

T300 Bobcat Loader


20-42-29 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-42-82
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Auxiliary Electric Solenoid Disassembly

Figure 20-42-80

3 2

N-18992
1

Remove the coil (Item 1) and end plate (Item 2) [Figure


1 20-42-82].

N-18996 Remove the solenoid valve (Item 3) [Figure 20-42-82].

Installation: Tighten valve to 8-12 ft.-lb. (11-16 N•m)


Remove the nut (Item 1) [Figure 20-42-80] from both
torque.
solenoids.
Figure 20-42-83
Installation: Tighten the nut to 8-12 ft.-lb. (11-16 N•m)
torque.

Figure 20-42-81

1 N-18795

Remove the O-rings (Item 1) [Figure 20-42-83] from the


N-18823 solenoid valves.

Remove the end plate (Item 1) and housing (Item 2)


[Figure 20-42-81].

T300 Bobcat Loader


20-42-30 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Cleaning And Inspection
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D) Clean all components with clean solvent and dry with
compressed air.
Port-Auxiliary Section Disassembly
Check the spools for wear or scratches.
Figure 20-42-84
Check that the spools are not loose in their bore.

Check that the centering springs are not broken.

Check that the load check valve seats are not worn.

Check the load check poppets for damage.

Check the rubber boots and retainers

1 Replace the parts as needed.

Use new O-rings and back-up rings.


N-18996
Apply oil to all new O-rings and back-up rings before
installation.
Remove the plug (Item 1) [Figure 20-42-84] or optional
port relief valve from the control valve.

NOTE: Optional port relief (Item 1) [Figure 20-42-84]


is either 2500 PSI or 3000 PSI depending on
the option used.

Figure 20-42-85

Port Relief (Optional)

2
1

1
N-18843

Remove the O-rings (Item 1) [Figure 20-42-85] &


[Figure 20-42-85] and back-up ring (Item 2) [Figure 20-
42-85] & [Figure 20-42-85] from the plug.

T300 Bobcat Loader


20-42-31 Service Manual
T300 Bobcat Loader
20-42-32 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL)

Identification IMPORTANT
Figure 20-43-1 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1
Figure 20-43-2

1
P-54236

The hydraulic control valve (1 piece casting) (foot control)


(Item 1) [Figure 20-43-1] does not have a removable
BICS™ section.

The BICS™ section and main control valve are in one


casting. P-54497

For identification of the hydraulic control valve (2 piece


Raise the lift arms and install an approved lift arm support
casting) (foot control), (See Identification on Page 20-40-
device.
1.)
Stop the engine. Raise the seat bar.
Removal And Installation
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)

Drain the hydraulic reservoir. (See Replacing Hydraulic


Fluid And Case Drain Filters on Page 10-120-3.)

Remove the control panel. (See Removal And Installation


on Page 50-100-1.)

Clean area around control valve.

Open rear door.


WARNING The fixed end main valve hose assembly (Item 1) [Figure
20-43-2] is connected to a fixed end fitting on the control
Never work on a machine with the lift arms up unless
valve. The hose is routed to the upright where the hose is
the lift arms are secured by an approved lift arm
connected to a fitting that feeds the base end of both lift
support device. Failure to use an approved lift arm
cylinders. The hose can only be removed by first
support device can allow the lift arms or attachment
removing it from the tee fitting located at the rear of the
to fall and cause injury or death.
W-2059-0598
loader.

Cap and plug the hose and fitting.

T300 Bobcat Loader


20-43-1 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-5
(FOOT CONTROL) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-43-3

1
2

2
P-54486

Disconnect the harness connector (Item 2) [Figure 20-


43-5] from the auxiliary valve solenoid.
P-54487
Disconnect the charge pressure sender wire connector
(Item 2) [Figure 20-43-5] from the charge pressure
Mark all hydraulic hoses and tubelines to aid in assembly. sender.

Remove the lift arm by-pass valve and mount from the Figure 20-43-6
loader. (See Removal And Installation on Page 20-50-1.)

Disconnect the tubeline (Item 1) [Figure 20-43-3] that


goes from the control valve to the hydraulic cooler.

Disconnect the hose (Item 2) [Figure 20-43-3] that goes


from the control valve to the hydraulic cooler. 1

Figure 20-43-4

2
3

P-54488

Disconnect foot control linkage (Item 1) [Figure 20-43-6]


2 from the tilt spool on the control valve.

Disconnect foot control linkage (Item 2) [Figure 20-43-6]


from the lift spool on the control valve.

1 P-54500 Move the control linkages to allow clearance for the


control valve removal.

Mark the four wire connectors for proper installation.

Disconnect the wire harness connectors (Item 1) from the


BICS™ valve solenoid, (Item 2) from auxiliary valve
solenoid and (Item 3) from the lift and tilt lock solenoids
[Figure 20-43-4].

T300 Bobcat Loader


20-43-2 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-9
(FOOT CONTROL) (CONT’D)

Removal And Installation (Cont’d) 1

Figure 20-43-7

P-62618

NOTE: Lifting chains were removed for photo clarity

P-54489 Remove the tubeline clamp mount bolt and clamp (Item
1) [Figure 20-43-9].

Loosen the fixed end main valve hose assembly (Item 1) NOTE: Removing the tubeline clamp will help provide
[Figure 20-43-7] from the control valve. added clearance for removing the valve.

The hose can be removed from the control valve by Figure 20-43-10
rotating the hose assembly.

Cap the hose and plug the fitting.

Figure 20-43-8

P-54492

Remove the tubeline clamp mount bolt and clamp (Item


1) [Figure 20-43-10].
P-54490

Install a chain hoist (Item 1) [Figure 20-43-8] to the


control valve, and support the control valve.

Loosen all the tubeline fittings connected to the control


valve.

T300 Bobcat Loader


20-43-3 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-13
(FOOT CONTROL) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-43-11 1

P-54495

Disconnect the tilt tubeline (Item 1) [Figure 20-43-13]


from the control valve.
P-62619
Disconnect the lift tubeline (Item 2) [Figure 20-43-13]
from the control valve.
Remove the two control valve mount bolts (Item 1)
[Figure 20-43-11] located on the outside of the frame. Figure 20-43-14

Installation: Torque the bolts (Item 1) [Figure 20-43-11]


to 90-100 ft. lb. (123-135 N•m).

Figure 20-43-12
1

P-54496

1 Disconnect the tilt tubeline (Item 1) [Figure 20-43-14]


from the control valve.
P-54494
Cap and plug the tubeline and fitting.

Disconnect the two auxiliary tubelines (Item 1) [Figure Remove the control valve from the loader.
20-43-12] from the control valve.

T300 Bobcat Loader


20-43-4 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)

Identification Chart
Figure 20-43-15

J2 C3
C2 J4
D5 B3
E3 E3
G1 G2
F2
A3
D3
B2
D4 A2 E2
F4

A1 D2
E1
F1 F3 B1 H3
H2
D1 J3
MR H1 C1

J1 MS1937

ITEM T300 LOADER


ITEM T300 LOADER
A1 Lift Cylinder Base End
E1 Lift Spool Detent
A2 Tilt Cylinder Base End
E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End
E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 LIft Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check/BICS™ Valve F4 Tilt Spool Lock Solenoid
Lift
G1 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function
G2 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function
H1 BICS™ Valve Solenoid
D1 Anti-Cavitation Valve
Lift (Rod End) H2 BICS™ Lock Valve (Tilt)
D2 Port Relief/Anti-Cavitation Valve – 4000 PSI H3 BICS™ Lock Valve (Lift)
Lift (Base End)
J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve – 4000 PSI
Tilt (Base End) J2 Outlet Fluid Flow (Return to Tank)
D4 Port Relief/Anti-Cavitation Valve – 4000 PSI J3 Lift Arm By-Pass Orifice
Tilt (Rod End) J4 Drain (Case)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary) MR Main Relief Valve – 3300 PSI
3500 PSI (Optional)

T300 Bobcat Loader


20-43-5 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-18
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Lift Load Check Valve Removal And


Installation

Figure 20-43-16 1

1 3
P-54292

Remove and install new O-rings (Item 1) and back-up


ring (Item 2) [Figure 20-43-18].

P-54237 Check the load check valve (Item 3) [Figure 20-43-18].

Remove the charge tubeline (Item 1) [Figure 20-43-16]


from the BICS valve fitting on the top of the lift load check
valve.

Figure 20-43-17

P-54238

Remove the lift load check valve (Item 1) [Figure 20-43-


17] and fitting from the top of the control valve.

Installation: Lubricate the O-ring and threads and


tighten to 55-65 ft.-lb. (75-88 N•m) torque.

T300 Bobcat Loader


20-43-6 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Anti-Cavitation Valve (Lift, Rod End)
(FOOT CONTROL) (CONT'D)
Figure 20-43-21
Load Check Valve Removal And Installation (Tilt &
Auxiliary)

Figure 20-43-19

2
1

1
P-51692

At the back side of the control valve, remove the lift


P-54243
section anti-cavitation valve (Item 1) [Figure 20-43-21].

At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-43-19].

At the front side of the control valve locate the auxiliary


WARNING
section load check valve (Item 2) [Figure 20-43-19].
When repairing hydrostatic and hydraulic systems,
NOTE: The tilt and auxiliary load check valves are clean the work area before disassembly and keep all
interchangeable. parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Figure 20-43-20 damage the system.
I-2003-0888

Figure 20-43-22
4

1
3
2

P-51453

1
Remove the spring (Item 1) and poppet (Item 2) [Figure
P-51693
20-43-20].

Check the orifice (Item 3) [Figure 20-43-20] in the Installation: Always use new O-ring (Item 1) [Figure 20-
poppet to be sure it is not plugged.
43-22] on the anti-cavitation valve plug. Tighten the plug
Installation: Install a new O-ring (Item 4) [Figure 20-43- to 38-45 ft.-lb. (52-61 N•m) torque.
20] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lb. (52-61 N•m)
torque.

T300 Bobcat Loader


20-43-7 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Lift, Base End)
(FOOT CONTROL) (CONT'D)
Figure 20-43-24
Anti-Cavitation Valve (Lift, Rod End) (Cont’d)

Figure 20-43-23

1
1
3
2

P-51692

P-51453 Loosen the lift circuit port relief/anti cavitation valve (Item
1) [Figure 20-43-24].

Remove the spring (Item 1) and poppet (Item 2) [Figure Figure 20-43-25
20-43-23].

Check the orifice (Item 3) [Figure 20-43-23] in the


poppet to be sure it is not plugged.

Installation: Install a new O-ring (Item 4) [Figure 20-43-


23] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lb. (52-61 N•m)
torque.

P-51451

Replace the O-ring (Item 1) [Figure 20-43-25] before


installation.

Installation: Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-43-8 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
(FOOT CONTROL) (CONT'D)
Figure 20-43-28
Port Relief/Anti-Cavitation Valve (Tilt, Base End)

Figure 20-43-26

P-51692

P-51692 Remove the tilt port relief/anti cavitation valve (Item 1)


[Figure 20-43-28] from the rod end of the tilt section.

Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-43-29
[Figure 20-43-26] from the base end of the tilt section.

Figure 20-43-27

1
P-51694

P-51454 Replace the O-ring (Item 1) [Figure 20-43-29] before


installation.

Replace the O-ring (Item 1) [Figure 20-43-27] before Installation: Tighten to 38-45 ft.-lb. (52-61 N•m) torque.
installation.

Installation: Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-43-9 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-32
(FOOT CONTROL) (CONT'D)

Port Relief Valve


1
Figure 20-43-30

P-51696

The control valve may be equipped with an optional


auxiliary port relief valve (Item 1) [Figure 20-43-32].
P-51692
Remove the auxiliary port relief valve.

Remove the port relief plug (Item 1) [Figure 20-43-30] Figure 20-43-33
from the auxiliary circuit of the control valve.

Figure 20-43-31

P-51640
1

P-51695 Installation: Always use new O-rings (Item 1) [Figure


20-43-33]. Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

Installation: Always use new O-rings (Item 1) [Figure


20-43-31]. Tighten to 38-45 ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-43-10 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-36
(FOOT CONTROL) (CONT'D)

Plug Removal

Figure 20-43-34

1
P-51461

At the bottom side of the control valve remove the plug


(Item 1) [Figure 20-43-36].
P-51459
Figure 20-43-37

At the top side of the control valve, remove the plug (Item
1) [Figure 20-43-34].

Figure 20-43-35

P-51462

Installation: Always use new O-rings (Item 1) [Figure


1 20-43-37]. Tighten to 40 ft.-lb. (54 N•m) torque.
P-51460

Installation: Always use new O-rings (Item 1) [Figure


20-43-35]. Tighten to 40 ft.-lb. (54 N•m) torque.

T300 Bobcat Loader


20-43-11 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Rubber Boot Removal and Installation

Figure 20-43-38

P-51506

Remove the three screws (Item 1) [Figure 20-43-38] on


the rubber boot retainer plate.

Installation: Tighten the screws to 90-100 in.-lb. (10-11,3


N•m) torque.

Figure 20-43-39

1
2

P-51701

Remove the rubber boots (Item 1) from the retainer plate


(Item 2) [Figure 20-43-39].

T300 Bobcat Loader


20-43-12 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-42
(FOOT CONTROL) (CONT'D)

End Cap/Spool Lock Block Removal and Installation

Figure 20-43-40

1 1

P-51699
1

Remove the four end cap/spool lock block mount screws


(Item 1) [Figure 20-43-42].
P-51697
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3
N•m) torque.
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-43-40] from the Remove the rubber boots and retainer plate from the lift
end cap/spool lock block. and tilt spools.

Figure 20-43-41 Figure 20-43-43

1
P-54244
P-54245

Disconnect the tube line (Item 1) [Figure 20-43-41] from Remove the end cap/spool lock block (Item 1) [Figure
the end cap/spool lock block. 20-43-43] from the control valve.

T300 Bobcat Loader


20-43-13 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-46
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation

The tool listed will be needed to do the following


procedure:

MEL1278 - Detent Tool


MEL1285 - Detent Spring Tool 1

Remove the end cap/spool lock block from the control


valve.

Figure 20-43-44
P-54246

Remove the end cap (Item 1) [Figure 20-43-46].

1 Figure 20-43-47

P-54245
1
Remove the O-ring (Item 1) [Figure 20-43-44]. 2

Installation: Replace the O-ring, and lubricate the o-ring


lightly with grease or oil before installation of the end cap/
P-51514
spool lock block.

Figure 20-43-45 Use a screwdriver to remove the snap ring (Item 1)


[Figure 20-43-47].

Remove the washer (Item 2) [Figure 20-43-47].

P-51512

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-43-45] from the lift spool.

T300 Bobcat Loader


20-43-14 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-49
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-43-48

1 P-51516

Put a rag around the detent assembly [Figure 20-43-49].


This will prevent the detent balls and spring from being
1 lost when the detent sleeve is removed.
2
P-51515
Figure 20-43-50

Remove the screws (Item 1) [Figure 20-43-48] from the


detent bonnet.

Remove the detent bonnet (Item 2) [Figure 20-43-48].

Installation: Lubricate the screws and tighten to 90-100


in.-lb. (10-11,3 N•m) torque.
2 1
3

WARNING
The detent assembly has small springs and balls. Do 2 P-51517
not lose these parts during disassembly and
assembly.
Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-43-50].

T300 Bobcat Loader


20-43-15 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-53
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-43-51

P-8988

Clamp the linkage end of the spool in a vise [Figure 20-


1 43-53].

P-51518 NOTE: Protect spool before clamping in vise.

Figure 20-43-54
Remove the lift spool assembly and seal (Item 1) [Figure
20-43-51] from the control valve. 2

Figure 20-43-52

1
3

1
N-18915

Install the spring tool (Item 1) [Figure 20-43-54] over the


P-51519 centering spring.

NOTE: Be careful when removing the detent adapter


Remove the lift spool seal (Item 1) [Figure 20-43-52] (Item 2) [Figure 20-43-54] from the centering
from the linkage end of the valve. spring, as it is under spring pressure.

T300 Bobcat Loader


20-43-16 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-57
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation 1


(Cont'd)

Figure 20-43-55

N-19009

Remove spring tool (Item 1) [Figure 20-43-57] from the


1 spring assembly.
2
N-18916 Figure 20-43-58

Put a rag around the detent assembly [Figure 20-43-55]. 1


2
This will prevent the detent balls and spring from being
lost when the detent adapter is removed. 3

Remove the detent adapter with an Alan wrench.


4
Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-43-55].

Figure 20-43-56

1
N-18919A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-43-58].

N-19004

Remove the detent adapter (Item 1) [Figure 20-43-56]


from the spring assembly.

T300 Bobcat Loader


20-43-17 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-61
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)
2
Figure 20-43-59
1

N-18961

Install the O-ring (Item 1) over the nipple on the plastic


plug (Item 2) [Figure 20-43-61].

N-18918 Figure 20-43-62

Remove the stud from the end of the spool [Figure 20-
43-59].

Figure 20-43-60

N-18963
1

Install the plastic plug and O-ring in the spool [Figure 20-
43-62].
N-18920

Removal of the plastic plug:

Make a center point in the plug using a 1/16 inch drill.

Drill a hole all the way through the plug using a 7/64 inch
tap drill

Turn a 6-32 tap (Item 1) [Figure 20-43-60] into the plug.


Pull the tap and plug out of the spool. Be careful, do not
break the tap.

Clean all the debris from inside the spool bore.

NOTE: DO NOT USE LOCTITE ON THE STUD


THREADS.

T300 Bobcat Loader


20-43-18 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-65
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)
2
Figure 20-43-63

O-ring

1 3
2

N-18958
Plastic
Plug
0.60 inch Apply grease on all the detent component surfaces
(15,2 mm)
before assembly [Figure 20-43-65].

B-14712 Install the spring (Item 1) [Figure 20-43-65] and detent


balls (Item 2) [Figure 20-43-65] into the adapter (Item 3)
[Figure 20-43-65] and compress with the detent pliers
Install the stud and tighten until the other end of the stud (Item 1) [Figure 20-43-66].
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-43-63]. Figure 20-43-66

Figure 20-43-64

N-18968

N-18967
Install the detent adapter to the collar [Figure 20-43-66].

Clamp the collar (Item 1) [Figure 20-43-64] in a vice. NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

T300 Bobcat Loader


20-43-19 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-69
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-43-67

N-19005

Install the spring assembly to the lift spool hand tight


[Figure 20-43-69].

N-19004 Remove the spring tool.

Check the alignment of the detent adapter and the


Install the spring tool (Item 1) [Figure 20-43-67] over the washer.
washer, spring, collar and detent adapter.
Tighten the adapter to 90-100 in.-lb. (10,2-11,3 N•m).
Figure 20-43-68
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-43-69].

Figure 20-43-70
2

N-18917

Install the spool seal (Item 1) and back-up washer (Item


2) [Figure 20-43-68].
CD-15051

Install the detent balls and spring [Figure 20-43-70].

T300 Bobcat Loader


20-43-20 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-73
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-43-71

2
P-51515

Install the lift spool assembly in the spool bore [Figure


20-43-73].

N-19007 Install the detent bonnet (Item 1) [Figure 20-43-73].

Install the mounting screws (Item 2) [Figure 20-43-73].


Hold the detent balls in place with the detent pliers
[Figure 20-43-71]. Installation: Lubricate the screws and tighten to 90-100
in.-lb. (10-11,3 N•m) torque.
Figure 20-43-72
Figure 20-43-74

1
N-19008

P-51514

Install the detent sleeve (Item 1) [Figure 20-43-72] to the


detent adapter. Install the washer (Item 1) and snap ring (Item 2) [Figure
20-43-74].

T300 Bobcat Loader


20-43-21 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-77
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-43-75

1
P-51512

Install the O-ring (Item 1) and bushing (Item 2) [Figure


20-43-77] on the lift spool.

P-54246 Figure 20-43-78

Install the end cap (Item 1) [Figure 20-43-75].

Figure 20-43-76
1

P-51511

Install the O-ring (Item 1) [Figure 20-43-78] on the


control valve.
P-51520

Install the spool seal (Item 1) [Figure 20-43-76] on the


linkage end of the valve.

T300 Bobcat Loader


20-43-22 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-81
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-43-79
2

1
P-51697

3
Use an Ohm meter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 5.5 ±.28 Ohms.

Installation: Install the lift spool (Item 1) and tilt spool


Install the end cap/spool lock block (Item 1) and the (Item 2) lock solenoids and tighten to 38-45 ft.-lb. (52-61
mount bolt (Item 2) [Figure 20-43-79]. N•m) torque [Figure 20-43-81].

Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-43-79].

Installation: Tighten the screws to 90-100 in.-lb. (10-11,3


N•m) torque.

Figure 20-43-80

P-54244

Connect the tubeline (Item 1) [Figure 20-43-80].

T300 Bobcat Loader


20-43-23 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-84
(FOOT CONTROL) (CONT'D)

Tilt Spool Removal and Installation

Remove the lift and tilt end cap/spool lock block. (See
End Cap/Spool Lock Block Removal and Installation on
Page 20-43-13.)
2
Figure 20-43-82

P-51543

Remove the spool centering block (Item 1) [Figure 20-


1 2
43-84] from the control valve.

Installation: Replace the O-ring (Item 2) [Figure 20-43-


84] and lubricate the o-ring lightly with grease or oil
before installation of the end cap/spool lock block.
P-51521
Figure 20-43-85

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-43-82] from the tilt spool.

Figure 20-43-83

2 P-51544
1
Remove the tilt spool, centering spring, back-up washer
and spool seal [Figure 20-43-85].
2 P-54247
Assembly: Always use a new spool seal.

Disconnect the two tubelines (Item 1) [Figure 20-43-83]


from the spool centering block.

Remove the three screws (Item 2) [Figure 20-43-83]


from the spool centering block.

Installation: Tighten the bolt to 90-100 in.-lb. (10-11,3


N•m) torque.

T300 Bobcat Loader


20-43-24 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-88
(FOOT CONTROL) (CONT'D)

Tilt Spool Removal And Installation (Cont'd)


2 1
Figure 20-43-86
3

4
1

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-43-88].
N-18942
Figure 20-43-89

Put the linkage end of the spool in the vice [Figure 20-
43-86]. 2
1
Install the spool tool (Item 1) [Figure 20-43-86] over the
centering spring.

Figure 20-43-87

1
1

P-51545 N-18943

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-43-89].

Assembly: Always use a new spool seal.

N-19014

Remove the bolt (Item 1) [Figure 20-43-87] holding the


centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.

Remove spring tool from the spring assembly.

T300 Bobcat Loader


20-43-25 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-92
(FOOT CONTROL) (CONT'D)

Auxiliary Spool Removal And Installation

Figure 20-43-90

1
3 2
1
1
2 P-51547

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-43-92] from the auxiliary spool.
2 P-54247
Figure 20-43-93

Remove the two tubelines (Item 1) [Figure 20-43-90]


from the spool centering block.

Remove the three screws (Item 1) [Figure 20-43-90]


from the spool centering block.

Installation: Tighten the bolt to 90-100 in.-lb. (10-11,3


2
N•m) torque.
1
Remove the spool centering block (Item 3) [Figure 20-
43-90] from the control valve.

Figure 20-43-91
P-51549

Remove the spring (Item 1) and center spring retainer


(Item 2) [Figure 20-43-93] from the auxiliary spool.

NOTE: If the centering spring retainer (Item 2) [Figure


2 20-43-93] must be replaced, replace the
1 retainer on the opposite end also.

P-51546

Remove the spring (Item 1) and center spring retainer


(Item 2) [Figure 20-43-91] from the auxiliary spool.

Note: If the centering spring retainer (Item 2) [Figure


20-43-91] must be replaced, replace the
retainer on the opposite end also.

T300 Bobcat Loader


20-43-26 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Auxiliary Spool Removal And Installation (Cont’d)

Figure 20-43-94

1
2

P-51550

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-43-94] from the auxiliary spool.

Figure 20-43-95

P-51551

Remove the spool (Item 1) [Figure 20-43-95].

T300 Bobcat Loader


20-43-27 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-98
(FOOT CONTROL) (CONT'D)

Auxiliary Solenoid Disassembly and Assembly

Figure 20-43-96
1

P-51703

Remove the solenoid stem (Item 1) [Figure 20-43-98].

P-51702 Installation: Tighten the stem to 10-14 ft.-lb. (14-19 N•m)


torque.

Remove the nut (Item 1) [Figure 20-43-96] from both Figure 20-43-99
solenoids.

Installation: Tighten the nut to 48-72 in.-lb. (5-8 N•m)


torque.

Figure 20-43-97
1

2
2
P-51555

Remove the O-rings (Item 1) [Figure 20-43-99] from the


solenoid stem.

P-51553 Check and clean the screen (Item 2) [Figure 20-43-99].

Remove the nut (Item 1) and solenoid coil (Item 2)


[Figure 20-43-97].

Use an Ohm meter to measure the solenoid coil


resistance.

The correct resistance for the coil is 4.9 ±.25 Ohms.

T300 Bobcat Loader


20-43-28 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-102
(FOOT CONTROL) (CONT'D)

BICS™ Valve Solenoid Disassembly And Assembly

Figure 20-43-100 1

1
2

P-54249

Remove the solenoid stem (Item 1) [Figure 20-43-102].

P-54248 Installation: Lubricate the O-rings and tighten the stem


to 20-24 ft.-lb. (27-33 N•m) torque.

Remove the nut (Item 1) [Figure 20-43-100] from the Figure 20-43-103
solenoid stem.

Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.

Remove the solenoid coil (Item 2) [Figure 20-43-100]. 3


2
Figure 20-43-101

N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-43-103] from the stem.

Clean all parts in solvent and dry with compressed air.


N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-43-101] from
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-43-103] may be
cleaned with solvent. If it is torn or worn it
Use an Ohm meter to measure the solenoid coil needs to be replaced.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.79 ±.29 Ohms. back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-43-101] &


[Figure 20-43-103] and new back-up rings (Item 2)
[Figure 20-43-103] on the solenoid stem.

T300 Bobcat Loader


20-43-29 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-106
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Lock Valve Removal And Installation

Figure 20-43-104 1
1
1

2
1 1
2
2
2
P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-43-106] from the lift lock valve, and replace
P-54250 with new.

Figure 20-43-107
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-43-104] is for the lift
circuit.

Figure 20-43-105

1 P-51705

Locate the tilt circuit lock valve (Item 1) [Figure 20-43-


107].
P-54251

Remove the lift lock valve (Item 1) [Figure 20-43-105]


from the back of the control valve.

Installation: Lightly lubricate the lock valve o-rings and


tighten to 20-24 ft.-lb. (27-33 N•m) torque.

T300 Bobcat Loader


20-43-30 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-110
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Lock Valve Removal And Installation


(Cont’d)
1
Figure 20-43-108
1
1

1
2
2
2
2
P-51564
1

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-43-110] from the tilt lock valve, and replace
with new.
P-51697

Remove the lift spool lock solenoid (Item 1) [Figure 20-


43-108].

Remove the tilt spool lock solenoid (Item 2) [Figure 20-


43-108].

Installation: Lubricate the O-rings and tighten the spool


lock solenoids to 38-45 ft.-lb. (52-61 N•m) torque.

Figure 20-43-109

P-51706

Remove the tilt lock valve (Item 1) [Figure 20-43-109]


from the front of the control valve.

Installation: Lightly lubricate the lock valve o-rings and


tighten to 20-24 ft.-lb. (27-33 N•m) torque.

T300 Bobcat Loader


20-43-31 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Lift Arm By-Pass Orifice Disassembly


And Assembly

Figure 20-43-111

P-54252

Remove the fitting (Item 1) [Figure 20-43-111] from the


valve.

Figure 20-43-112

P-51437

Check the lift arm by-pass orifice (Item 1) [Figure 20-43-


112].

NOTE: This orifice is not removable from the valve


casting.

T300 Bobcat Loader


20-43-32 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Main Relief Valve

Figure 20-43-113

P-51707

Remove the main relief valve (Item 1) [Figure 20-43-


113].

Figure 20-43-114

P-51463

Remove the O-rings from the main relief valve (Item 1)


[Figure 20-43-114].

Installation: Always use new O-rings. Tighten to 38-45


ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-43-33 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-117
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Check Valve Removal and Installation

Figure 20-43-115
1

P-54239

Check the fitting screen (Item 1) [Figure 20-43-117].

P-54237 Figure 20-43-118

Remove the charge tubeline (Item 1) [Figure 20-43-115]


from the fitting on the top of the lift load check valve.

Figure 20-43-116

P-54240

Inspect the fitting check valve (Item 1) [Figure 20-43-


118].

P-54238

Remove the BICS check valve fitting (Item 1) [Figure 20-


43-116] from the top of the lift load check valve.

Installation: Lubricate the O-ring and threads and


tighten to 20-24 ft.-lbs (27-33 N•m) torque.

T300 Bobcat Loader


20-43-34 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS)

Identification

Figure 20-44-1

P-54336

The hydraulic control valve (1 piece casting) (ACS) (Item


1) [Figure 20-44-1] does not have a removable BICS™
section.

The BICS™ section and main control valve are in one


casting.

For identification of the hydraulic control valve (2 piece


casting), (See Identification on Page 20-41-1.)

T300 Bobcat Loader


20-44-1 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-2
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal And Installation

WARNING P-54497

Never work on a machine with the lift arms up unless The fixed end main valve hose assembly (Item 1) [Figure
the lift arms are secured by an approved lift arm 20-44-2] is connected to a fixed end fitting on the control
support device. Failure to use an approved lift arm valve. The hose is routed to the upright where the hose is
support device can allow the lift arms or attachment connected to a fitting that feeds the base end of both lift
to fall and cause injury or death. cylinders. The hose can only be removed by first
W-2059-0598 removing it from the tee fitting located at the rear of the
loader.

Figure 20-44-3

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 1

Raise the lift arms and install an approved lift arm support
device.

Stop the engine. Raise the seat bar.


P-54569

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.) Remove the tubeline clamp (Item 1) [Figure 20-44-3]
located on the inside of the left upright.
Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid And Case Drain Filters on Page 10-120-3.)

Remove the control panel. (See Removal And Installation


on Page 50-100-1.)

Clean area around control valve.

Remove the lift arm by-pass valve. (See Removal And


Installation on Page 20-50-1.)

Open rear door.

T300 Bobcat Loader


20-44-2 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-6
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-44-4

2
P-54486

Disconnect the harness connector (Item 2) [Figure 20-


44-6] from the auxiliary valve solenoid.
P-54570
Disconnect the charge pressure sender wire connector
(Item 2) [Figure 20-44-6] from the charge pressure
Mark the two wire connectors for proper installation. sender.

Disconnect the wire harness connector (Item 1) from the Figure 20-44-7
BICS™ valve solenoid and (Item 2) from auxiliary valve
solenoid [Figure 20-44-4].

Figure 20-44-5

1
2
2

P-54487

Disconnect the tubeline (Item 1) [Figure 20-44-7] that


P-54564 goes from the control valve to the hydraulic cooler.

Disconnect the hose (Item 2) [Figure 20-44-7] that goes


Disconnect the lift and tilt actuator electrical connectors from the control valve to the gear pump.
(Item 1) and (Item 2) [Figure 20-44-5] from the control
valve.

T300 Bobcat Loader


20-44-3 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-10
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-44-8

P-54492

Remove the tubeline clamp mount bolt and clamp (Item


1) [Figure 20-44-10].
P-54489
Figure 20-44-11

Loosen the fixed end main valve hose assembly (Item 1)


[Figure 20-44-8] from the control valve.

The hose can be removed from the control valve by


rotating the hose assembly.

Cap the hose and plug the fitting.

Figure 20-44-9

1 P-54494

Disconnect the two auxiliary tubelines (Item 1) [Figure


20-44-11] from the control valve.

P-54572

Install a chain hoist (Item 1) [Figure 20-44-9] to the


control valve, and support the control valve.

Loosen all the tubeline fittings connected to the control


valve.

T300 Bobcat Loader


20-44-4 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-14
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-44-12
1

P-62619

2
Remove the two control valve mount bolts (Item 1)
[Figure 20-44-14] located on the outside of the frame.
P-54573
Installation: Torque the bolts (Item 1) [Figure 20-44-14]
to 90-100 ft. lb. (123-135 N•m).
Disconnect the tilt tubeline (Item 1) [Figure 20-44-12]
from the control valve. Figure 20-44-15

Disconnect the tilt tubeline (Item 2) [Figure 20-44-12]


from the control valve. (If equipped with Bucket
Positioning Valve.)

Disconnect the lift tubeline (Item 3) [Figure 20-44-12]


from the control valve.

Figure 20-44-13
1

1
P-62618

NOTE: Lifting chains were removed for photo clarity

Remove the tubeline clamp mount bolt and clamp (Item


1) [Figure 20-44-15] from the mounting plate.

NOTE: Removing the tubeline clamp will help provide


P-54496 added clearance for removing the valve.

Remove the control valve from the loader.


Disconnect the tilt tubeline (Item 1) [Figure 20-44-13]
from the control valve.

Cap and plug the tubeline and fitting.

T300 Bobcat Loader


20-44-5 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-17
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Actuator Removal And Installation (In Loader)

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-54587

Raise the lift arms and install an approved lift arm support
device. (See Installing The Lift Arm Support Device on Remove the two screws (Item 1) [Figure 20-44-17] from
Page 10-20-1.) the actuator retainer.

Stop the engine. Raise the seat bar. Installation: Tighten the bolts to 90-100 in.-lb. (10,2-11,3
N•m) torque.
Mark the actuator wiring harness connectors for proper
installation.

Figure 20-44-16

P-54564

Unplug the actuator connectors (Item 1) [Figure 20-44-


16] from the loader harness.

T300 Bobcat Loader


20-44-6 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-19
(ADVANCED CONTROL SYSTEM) (ACS) (CONT'D)

Actuator Removal And Installation (In Loader)


(Cont’d)

Figure 20-44-18

1
2

P-54568
2

1 Inspect the O-ring (Item 1) [Figure 20-44-19] on the face


of the actuator, and replace as needed.

P-54566 Check the linkage pin (Item 2) [Figure 20-44-19] and


replace as needed.

Pull the actuator (Item 1) [Figure 20-44-18] away from


the control valve.

Use a punch to remove the actuator pin (Item 2) [Figure


20-44-18] from the actuator and spool.

Remove the actuator from the hydraulic control valve.

NOTE: The calibration procedure must be followed


when replacing a lift or tilt actuator. (See Lift
and Tilt Calibration Procedure (Selectable
Joystick Control) (SJC) on Page 60-160-1.)

T300 Bobcat Loader


20-44-7 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-22
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Actuator Removal And Installation (Out of Loader)

Remove the control valve from the loader.

Figure 20-44-20

P-54339

Using a drift pin and a hammer, remove the actuator


1 linkage pin (Item 1) [Figure 20-44-22] from the actuator
and the tilt spool.

P-54337 Remove the actuator and linkage pin from the valve.

Figure 20-44-23
Remove the two mount bolts (Item 1) [Figure 20-44-20]
from the tilt actuator.

Installation: Tighten the mounting bolts to 90-100 in.-lb.


(10,2-11,3 N•m) torque.

Figure 20-44-21

P-54340

1 Inspect the O-ring (Item 1) [Figure 20-44-23] on the face


of the actuator, and replace as needed.

Check the linkage pin (Item 2) [Figure 20-44-23] and


P-54338 replace as needed.

Slide the actuator mount bracket (Item 1) [Figure 20-44-


21] away from the control valve.

Pull the actuator away from the control valve [Figure 20-
44-21].

T300 Bobcat Loader


20-44-8 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-26
(ADVANCED CONTROL SYSTEM) (ACS)(CONT’D)

Actuator Removal And Installation (Out of Loader)


(Cont’d)

Figure 20-44-24

1 1

P-54343

Using a drift pin and a hammer, remove the actuator


linkage pin (Item 1) [Figure 20-44-26] from the actuator
1 and the tilt spool.
P-54341
Remove the actuator and linkage pin from the valve.

Remove the two mount bolts (Item 1) [Figure 20-44-24] Figure 20-44-27
from the lift actuator.

Installation: Tighten the mounting bolts to 90-100 in.-lb.


(10,2-11,3 N•m) torque.

Figure 20-44-25

P-54340

Inspect the O-ring (Item 1) [Figure 20-44-27] on the face


1 of the actuator, and replace as needed.

P-54342 Check the linkage pin (Item 2) [Figure 20-44-27] and


replace as needed.

Slide the actuator mount bracket (Item 1) [Figure 20-44-


25] away from the control valve.

Pull the actuator away from the control valve [Figure 20-
44-25].

T300 Bobcat Loader


20-44-9 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Actuator Removal And Installation (Out of Loader)


(Cont’d)

Figure 20-44-28

1 2

3
P-51738

NOTE: The two longer bolts (Item 1) are used to


mount the lift actuator and end cap (Item 2)
[Figure 20-44-28] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-44-28].

Installation: Tighten the mounting bolts to 90-100 in.-lb.


(10,2-11,3 N•m) torque (Item 1) [Figure 20-44-28]

T300 Bobcat Loader


20-44-10 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Identification Chart

Figure 20-44-29

J2
C2 J4 C3
D5 B3 E3
E3
G1 G2

D3
B2 A3
D4 E2
F2
A2

D1 A1
E1 D2
H2 B1
F1 H3
MR C1
H1
J3
J1
MS1972

ITEM T300 LOADER ITEM T300 LOADER


A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 LIft Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Load Check/BICS™ Valve G2 Auxiliary Solenoid Stem
Lift H1 BICS™ Valve Solenoid
C2 Load Check Valve Tilt Function
H2 BICS™ Lock Valve (Tilt)
C3 Load Check Valve Auxiliary Function
D1 Anti-Cavitation Valve H3 BICS™ Lock Valve (Lift)
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief/Anti-Cavitation Valve – 4000 PSI J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End) J3 Lift Arm By-Pass Orifice
D3 Port Relief/Anti-Cavitation Valve – 4000 PSI J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 3300 PSI
D4 Port Relief/Anti-Cavitation Valve – 4000 PSI
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

T300 Bobcat Loader


20-44-11 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-32
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve, Lift Load Check Valve Removal And


Installation

Figure 20-44-30 1

1 3
P-54292

Remove and install new O-rings (Item 1) and back-up


ring (Item 2) [Figure 20-44-32].

P-54344 Check the load check valve (Item 3) [Figure 20-44-32].

Remove the charge tubeline (Item 1) [Figure 20-44-30]


from the BICS valve fitting on the top of the lift load check
valve.

Figure 20-44-31

P-54355

Remove the lift load check valve (Item 1) [Figure 20-44-


31] and fitting from the the top of the control valve.

Installation: Lubricate the O-ring and threads and


tighten to 55-65 ft.-lb. (75-88 N•m) torque.

T300 Bobcat Loader


20-44-12 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Anti-Cavitation Valve (Lift, Rod End)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-44-35
Load Check Valve Removal And Installation (Tilt &
Auxiliary)

Figure 20-44-33

2
1

P-51742

At the back side of the control valve, remove the lift


P-54345 section anti-cavitation valve (Item 1) [Figure 20-44-35].

At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-44-33].
WARNING
At the front side of the control valve locate the auxiliary
section load check valve (Item 2) [Figure 20-44-33]. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
NOTE: The tilt and auxiliary load check valves are parts clean. Always use caps and plugs on hoses,
interchangeable. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 20-44-34 I-2003-0888

4 Figure 20-44-36

1
3
2

P-51453

1
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-44-34].
P-51452
Check the orifice (Item 3) [Figure 20-44-34] in the
poppet to be sure it is not plugged.
Always use new O-ring (Item 1) [Figure 20-44-36] on the
Installation: Install a new O-ring (Item 4) [Figure 20-44- anti-cavitation valve plug.
34] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lb. (52-61 N•m)
torque.

T300 Bobcat Loader


20-44-13 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Lift, Base End)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-44-38
Anti-Cavitation Valve (Lift, Rod End) (Cont’d)

Figure 20-44-37

1
1
3
2

P-51742

P-51453 Loosen the lift circuit port relief/anti-cavitation valve (Item


1) [Figure 20-44-38].

Remove the spring (Item 1) and poppet (Item 2) [Figure Figure 20-44-39
20-44-37].

Check the orifice (Item 3) [Figure 20-44-37] in the


poppet to be sure it is not plugged.

Installation: Install a new O-ring (Item 4) [Figure 20-44-


37] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lb. (52-61 N•m)
torque.

P-51451

Replace the O-ring (Item 1) [Figure 20-44-39] before


installation.

Installation: Lightly lubricate with oil and tighten to 38-45


ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-44-14 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-44-42
Port Relief/Anti-Cavitation Valve (Tilt, Base End)

Figure 20-44-40

P-51742

P-51742 Remove the tilt port relief/anti cavitation valve (Item 1)


[Figure 20-44-42] from the rod end of the tilt section.

Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-44-43
[Figure 20-44-40] from the base end of the tilt section.

Figure 20-44-41

1
P-51455

P-51454 Replace the O-ring (Item 1) [Figure 20-44-43] before


installation.

Replace the O-ring (Item 1) [Figure 20-44-41] before Installation: Lightly lubricate with oil and tighten to 38-45
installation. ft.-lb. (52-61 N•m) torque.

Installation: Lightly lubricate with oil and tighten to 38-45


ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-44-15 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-46
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Port Relief Valve


1
Figure 20-44-44

P-51743

The control valve may be equipped with an optional


auxiliary port relief valve (Item 1) [Figure 20-44-46].
P-51742
Remove the auxiliary port relief valve.

Remove the port relief plug (Item 1) [Figure 20-44-44] Figure 20-44-47
from the auxiliary circuit of the control valve.

Figure 20-44-45

P-51640
1

P-51801 Installation: Always use new O-rings (Item 1) [Figure


20-44-47]. Lightly lubricate with oil and tighten to 38-45
ft.-lb. (52-61 N•m) torque.
Installation: Always use new O-rings (Item 1) [Figure
20-44-45]. Lightly lubricate with oil and tighten to 38-45
ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-44-16 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-50
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Plug Removal

Figure 20-44-48

1
P-51461

At the bottom side of the control valve remove the plug


(Item 1) [Figure 20-44-50].
P-51459
Figure 20-44-51

At the top side of the control valve, remove the plug (Item
1) [Figure 20-44-48].

Figure 20-44-49

P-51462

Installation: Always use new O-rings (Item 1) [Figure


1 20-44-51]. Tighten to 60 ft.-lb. (81,3 N•m) torque.
P-51460

Installation: Always use new O-rings (Item 1) [Figure


20-44-49]. Tighten to 60 ft.-lb. (81,3 N•m) torque.

T300 Bobcat Loader


20-44-17 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-53
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

End Cap Block Removal And Installation

Remove the lift and tilt actuators from the control valve.
(See Actuator Removal And Installation (In Loader) on
Page 20-44-6.)
1
Figure 20-44-52

P-54347

Remove the end cap block (Item 1) [Figure 20-44-53]


from the control valve.
1

2
P-54346

Disconnect the tube line (Item 1) [Figure 20-44-52] from


the end cap block.

Remove the two end cap block mount screws (Item 1)


[Figure 20-44-52].

Installation: Tighten the screws to 90-100 in.-lb. (10,2-


11,3 N•m) torque.

T300 Bobcat Loader


20-44-18 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-56
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift Spool Removal And Installation

The tool listed will be needed to do the following 1


procedure:

MEL 1285 - Spring Tool

Remove the end cap block from the control valve.

Figure 20-44-54

1
P-54348

Remove the two screws (Item 1) [Figure 20-44-56] from


1 the lift spool end cap.

Installation: Lubricate the screws and tighten to 90-100


in.-lb. (10,2-11,3 N•m) torque.

Figure 20-44-57

P-51746

Remove the O-ring (Item 1) [Figure 20-44-54].

Installation: Replace the O-ring, and lubricate lightly


with oil before installation of the end cap block.

Figure 20-44-55 1

P-51749

Remove the lift spool end cap (Item 1) [Figure 20-44-57]


2 from the control valve.
1

P-51747

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-44-55] from the lift spool.

T300 Bobcat Loader


20-44-19 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-60
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift Spool Removal And Installation (Cont'd)

Figure 20-44-58

P-51772

1 Clamp the linkage end of the spool in a vise [Figure 20-


44-60].
P-51770
NOTE: Protect spool before clamping in vise.

Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-44-61
20-44-58] from the control valve.

Figure 20-44-59

P-51773

P-51771 Install the spring tool (Item 1) [Figure 20-44-61] over the
centering spring.

Remove the lift spool seal (Item 1) [Figure 20-44-59]


from the linkage end of the valve.

T300 Bobcat Loader


20-44-20 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-64
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift Spool Removal And Installation (Cont'd)


2
1
Figure 20-44-62

P-51771 P-51775

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-44-64].
N-190146
Assembly: Always use a new spool seal.

Remove the bolt (Item 1) [Figure 20-44-62] holding the Figure 20-44-65
centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque. 1

Remove spring tool from the spring assembly.

Figure 20-44-63

2
3
3 3

4 1 P-51749

Install the lift spool assembly (Item 1) [Figure 20-44-65]


in the spool bore.

Install the end cap (Item 2) [Figure 20-44-65].

P-51776 Install the mounting screws (Item 3) [Figure 20-44-65].

Installation: Lubricate the screws and tighten to 90-100


Inspect the adapter (Item 1), collar (Item 2), spring (Item in.-lb. (10,2-11,3 N•m) torque.
3) and washer (Item 4) [Figure 20-44-63].

T300 Bobcat Loader


20-44-21 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-68
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift Spool Removal And Installation (Cont'd)


1
Figure 20-44-66

P-51746

Install the O-ring (Item 1) [Figure 20-44-68] on the


control valve.
P-51777
Installation: Replace the O-ring, lubricate lightly with oil
or grease before installation of the end cap block.
Install the spool seal (Item 1) [Figure 20-44-66] on the
linkage end of the valve. Figure 20-44-69

Figure 20-44-67

1
3 2

1
2
2
P-54346

P-51747
Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-44-69].
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-44-67] on the lift spool. Installation: Tighten the screws to 90-100 in.-lb. (10,2-
11,3 N•m) torque.

Connect the tubeline (Item 1) [Figure 20-44-69] to the


end cap block.

Install the lift and tilt actuators to the control valve.

T300 Bobcat Loader


20-44-22 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-72
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Tilt Spool Removal And Installation

Remove the end cap block. (See End Cap Block


Removal And Installation on Page 20-44-18.)

Figure 20-44-70 2

P-51780

Remove the spool centering block (Item 1) [Figure 20-


44-72] from the control valve.
1 2
Installation: Replace the O-ring (Item 2) [Figure 20-44-
72] and lubricate lightly with oil/grease before installation
P-51778 of the end cap block.

Figure 20-44-73
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-44-70] from the tilt spool.

Figure 20-44-71

1
1

2
1

P-51781

2 Remove the tilt spool, centering spring, back-up washer


P-54348 and spool seal (Item 1) [Figure 20-44-73].

Assembly: Always use a new spool seal.


Disconnect the two tubelines (Item 1) [Figure 20-44-71].

Remove the three screws (Item 2) [Figure 20-44-71]


from the spool centering block.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.

T300 Bobcat Loader


20-44-23 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-76
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Tilt Spool Removal And Installation (Cont'd)


2 1
Figure 20-44-74
3

4
1

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-44-76].
N-18942
Figure 20-44-77

Put the linkage end of the spool in the vice [Figure 20-
44-74]. 2
1
Install the spring tool (Item 1) [Figure 20-44-74] over the
centering spring.

Figure 20-44-75

1
1

P-51545 N-18943

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-44-77].

Assembly: Always use a new spool seal.

N-19014

Remove the bolt (Item 1) [Figure 20-44-75] holding the


centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.

Remove spring tool from the spring assembly.

T300 Bobcat Loader


20-44-24 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-80
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Auxiliary Spool Removal And Installation

Figure 20-44-78

2
1

1
1

2 P-51783

2 Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-44-80] from the auxiliary spool.
P-54349
Figure 20-44-81

Disconnect the two tubelines (Item 1) [Figure 20-44-78]


from the spool centering block.

Remove the three screws (Item 2) [Figure 20-44-78]


from the spool centering block.

Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3


N•m) torque.
1
Remove the spool centering block from the control valve.

Figure 20-44-79 2

P-51784

Remove the spring (Item 1) and center spring retainer


(Item 2) [Figure 20-44-81] from the auxiliary spool.

NOTE: If the centering spring retainer (Item 2) [Figure


20-44-81] must be replaced, replace the
retainer on the opposite end also.
2

1
P-51782

Remove the spring (Item 1) and center spring retainer


(Item 2) [Figure 20-44-79] from the auxiliary spool.

NOTE: If the centering spring retainer (Item 2) [Figure


20-44-79] must be replaced, replace the
retainer on the opposite end also.

T300 Bobcat Loader


20-44-25 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Auxiliary Spool Removal And Installation (Cont’d)

Figure 20-44-82

1
2

P-51785

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-44-82] from the auxiliary spool.

Figure 20-44-83

P-51786

Remove the auxiliary spool (Item 1) [Figure 20-44-83].

T300 Bobcat Loader


20-44-26 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-86
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Auxiliary Solenoid Disassembly And Assembly

Figure 20-44-84 1

P-54350

Remove the solenoid stem (Item 1) [Figure 20-44-86].

P-51552 Installation: Tighten the stem to 10-14 ft.-lb. (14-19 N•m)


torque.

Remove the nut (Item 1) [Figure 20-44-84] from both Figure 20-44-87
solenoids.

Installation: Tighten the nut to 48-72 in.-lb. (5-8 N•m)


torque.

Figure 20-44-85
1

2
2
P-51555

Remove the O-rings (Item 1) [Figure 20-44-87] from the


solenoid stem.

P-51553 Check and clean the screen (Item 2) [Figure 20-44-87].

Remove the nut (Item 1) and solenoid coil (Item 2)


[Figure 20-44-85].

Use an Ohmmeter to measure the solenoid coil


resistance.

The correct resistance for the coil is 4.9 ± .25 Ohms.

T300 Bobcat Loader


20-44-27 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-90
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve Solenoid Disassembly And Assembly

Figure 20-44-88

2
P-54352

Remove the solenoid stem (Item 1) [Figure 20-44-90].

P-54351 Installation: Lubricate the O-rings and tighten the stem


to 20-24 ft.-lb. (27-33 N•m) torque.

Remove the nut (Item 1) [Figure 20-44-88] from the Figure 20-44-91
solenoid stem.

Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.

Remove the solenoid coil (Item 2) [Figure 20-44-88]. 3


2
Figure 20-44-89

1
1

N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-44-91] from the stem.

Clean all parts in solvent and dry with compressed air.


N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-44-89] from
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-44-91] may be
cleaned with solvent. If it is torn or worn it
Use an Ohmmeter to measure the solenoid coil needs to be replaced.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.79 ± .29 Ohms. back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-44-89] & [Figure


20-44-91] and new back-up rings (Item 2) [Figure 20-44-
91] on the solenoid stem.

T300 Bobcat Loader


20-44-28 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-94
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve, Lock Valve Removal And Installation

Figure 20-44-92 1
1
1

2 1
1
2
2
2
P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-44-94] from the lift lock valve, and replace
P-54353 with new.

Figure 20-44-95
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-44-92] is for the lift circuit.

Figure 20-44-93

1 P-51792

Remove the tilt lock valve (Item 1) [Figure 20-44-95]


P-54354 from the back of the control valve.

Installation: Lightly lubricate the lock valve o-rings and


Remove the lift lock valve (Item 1) [Figure 20-44-93] tighten to 20-24 ft.-lb. (27-33 N•m) torque.
from the back of the control valve.

Installation: Lightly lubricate the lock valve o-rings and


tighten to 20-24 ft.-lb. (27-33 N•m) torque.

T300 Bobcat Loader


20-44-29 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve, Lock Valve Removal And Installation


(Cont’d)

Figure 20-44-96

1
1
1

1
2
2
2
P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-44-96] from the tilt lock valve, and replace
with new.

T300 Bobcat Loader


20-44-30 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Main Relief Valve
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-44-99
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly
And Assembly

Figure 20-44-97

P-51794

Remove the main relief valve (Item 1) [Figure 20-44-99].


P-54344
Figure 20-44-100

Remove the fitting (Item 1) [Figure 20-44-97] from the


valve.

Figure 20-44-98

1
1
P-51463

Remove the O-rings from the main relief valve (Item 1)


[Figure 20-44-100].
P-51437
Installation: Always use new O-rings. Tighten to 38-45
ft.-lb. (52-61 N•m) torque.
Check the lift arm by-pass orifice (Item 1) [Figure 20-44-
98].

NOTE: This orifice is not removable from the valve


casting.

T300 Bobcat Loader


20-44-31 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-44-103
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve, Check Valve Removal And Installation

Figure 20-44-101
1

P-54239

Check the fitting screen (Item 1) [Figure 20-44-103].

P-54344 Figure 20-44-104

Remove the charge tubeline (Item 1) [Figure 20-44-101]


from the fitting on the top of the lift load check valve.

Figure 20-44-102

1
1

P-54240

Inspect the fitting check valve (Item 1) [Figure 20-44-


104].

P-54355

Remove the BICS™ check valve fitting (Item 1) [Figure


20-44-102] from the top of the lift load check valve.

Installation: Lubricate the O-ring and tighten the valve to


20-24 ft.-lb. (27-33 N•m) torque.

T300 Bobcat Loader


20-44-32 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)

Identification

Figure 20-45-1

P-54336

The hydraulic control valve (1 piece casting) (SJC) (Item


1) [Figure 20-45-1] does not have a removable BICS™
section.

The BICS™ section and main control valve are in one


casting.

For identification of the hydraulic control valve (2 piece


casting), (See Identification on Page -1.)

T300 Bobcat Loader


20-45-1 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-2
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Removal And Installation

P-54497

WARNING
The fixed end main valve hose assembly (Item 1) [Figure
Never work on a machine with the lift arms up unless 20-45-2] is connected to a fixed end fitting on the control
the lift arms are secured by an approved lift arm valve. The hose is routed to the upright where the hose is
support device. Failure to use an approved lift arm connected to a fitting that feeds the base end of both lift
support device can allow the lift arms or attachment cylinders. The hose can only be removed by first
to fall and cause injury or death. removing it from the tee fitting located at the rear of the
W-2059-0598 loader.

Figure 20-45-3

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 1
I-2003-0888

Raise the lift arms and install an approved lift arm support
device.

Stop the engine. Raise the seat bar. P-54569

Raise the operator cab. (See Raising The Operator Cab Remove the tubeline clamp (Item 1) [Figure 20-45-3]
on Page 10-30-1.) located on the inside of the left upright.
Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid And Case Drain Filters on Page 10-120-3.)

Remove the control panel. (See Removal And Installation


on Page 50-100-1.)

Clean area around control valve.

Remove the lift arm by-pass valve. (See Removal And


Installation on Page 20-50-1.)

Open rear door.

T300 Bobcat Loader


20-45-2 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-6
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Removal And Installation (Cont’d)

Figure 20-45-4

1
2
P-54486

Disconnect the harness connector (Item 2) [Figure 20-


45-6] from the auxiliary valve solenoid.

P-54570 Disconnect the charge pressure sender wire connector


(Item 2) [Figure 20-45-6] from the charge pressure
sender.
Mark the two wire connectors for proper installation.
Figure 20-45-7
Disconnect the wire harness connector (Item 1) from the
BICS™ valve solenoid and (Item 2) from auxiliary valve
solenoid [Figure 20-45-4].

Figure 20-45-5
1
2

P-54487

Disconnect the tubeline (Item 1) [Figure 20-45-7] that


goes from the control valve to the hydraulic cooler.
P-54564

Disconnect the hose (Item 2) [Figure 20-45-7] that goes


from the control valve to the gear pump.
Disconnect the lift and tilt actuator electrical connectors
(Item 1) and (Item 2) [Figure 20-45-5] from the control
valve.

T300 Bobcat Loader


20-45-3 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-10
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Removal And Installation (Cont’d)

Figure 20-45-8

1
1

P-54492

Remove the tubeline clamp mount bolt and clamp (Item


1) [Figure 20-45-10].

P-54489 Figure 20-45-11

Loosen the fixed end main valve hose assembly (Item 1)


[Figure 20-45-8] from the control valve.

The hose can be removed from the control valve by


rotating the hose assembly.

Cap the hose and plug the fitting.

Figure 20-45-9

P-54494
1

Disconnect the two auxiliary tubelines (Item 1) [Figure


20-45-11] from the control valve.

P-54572

Install a chain hoist (Item 1) [Figure 20-45-9] to the


control valve, and support the control valve.

Loosen all the tubeline fittings connected to the control


valve.

T300 Bobcat Loader


20-45-4 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-14
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Removal And Installation (Cont’d)

Figure 20-45-12
1

3
P-62619

2 Remove the two control valve mount bolts (Item 1)


[Figure 20-45-14] located on the outside of the frame.

P-54573 Installation: Torque the bolts (Item 1) [Figure 20-45-14]


to 90-100 ft. lb. (123-135 N•m).
Disconnect the tilt tubeline (Item 1) [Figure 20-45-12]
Figure 20-45-15
from the control valve.

Disconnect the tilt tubeline (Item 2) [Figure 20-45-12]


from the control valve. (If equipped with Bucket
Positioning Valve.)

Disconnect the lift tubeline (Item 3) [Figure 20-45-12]


from the control valve.

Figure 20-45-13 1

1 P-62618

NOTE: Lifting chains were removed for photo clarity

Remove the tubeline clamp mount bolt and clamp (Item


1) [Figure 20-45-15] from the mounting plate.

NOTE: Removing the tubeline clamp will help provide


added clearance for removing the valve.
P-54496

Remove the control valve from the loader.


Disconnect the tilt tubeline (Item 1) [Figure 20-45-13]
from the control valve.

Cap and plug the tubeline and fitting.

T300 Bobcat Loader


20-45-5 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-17
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Actuator Removal And Installation (In Loader)


1

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 P-54587

Figure 20-45-16 Remove the two screws (Item 1) [Figure 20-45-17] from
the actuator retainer.

Installation: Tighten the bolts to 90-100 in.-lb. (10,2-11,3


N•m) torque.

P-54564

Raise the lift arms and install an approved lift arm support
device. (See Installing The Lift Arm Support Device on
Page 10-20-1.)

Mark the actuator wiring harness connectors for proper


installation.

Unplug the actuator connectors (Item 1) [Figure 20-45-


16] from the loader harness.

T300 Bobcat Loader


20-45-6 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-19
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT'D)

Actuator Removal And Installation (In Loader)


(Cont’d)

Figure 20-45-18

1
2

P-54568

2
Inspect the O-ring (Item 1) [Figure 20-45-19] on the face
1 of the actuator, and replace as needed.

Check the linkage pin (Item 2) [Figure 20-45-19] and


P-54566 replace as needed.

Pull the actuator (Item 1) [Figure 20-45-18] away from


the control valve.

Use a punch to remove the actuator pin (Item 2) [Figure


20-45-18] from the actuator and spool.

Remove the actuator from the hydraulic control valve.

NOTE: The calibration procedure must be followed


when replacing a lift or tilt actuator. (See Lift
and Tilt Calibration Procedure (Selectable
Joystick Control) (SJC) on Page 60-160-1.)

T300 Bobcat Loader


20-45-7 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-22
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Actuator Removal And Installation (Out of Loader)

Remove the control valve from the loader.

Figure 20-45-20

1
1

P-54339

Using a drift pin and a hammer, remove the actuator


linkage pin (Item 1) [Figure 20-45-22] from the actuator
1
and the tilt spool.

Remove the actuator and linkage pin from the valve.


P-54337

Figure 20-45-23
Remove the two mount bolts (Item 1) [Figure 20-45-20]
from the tilt actuator.

Installation: Tighten the mounting bolts to 90-100 in.-lb.


(10,2-11,3 N•m) torque.

Figure 20-45-21
1

P-54340

Inspect the O-ring (Item 1) [Figure 20-45-23] on the face


1 of the actuator, and replace as needed.

Check the linkage pin (Item 2) [Figure 20-45-23] and


replace as needed.
P-54338

Slide the actuator mount bracket (Item 1) [Figure 20-45-


21] away from the control valve.

Pull the actuator away from the control valve [Figure 20-
45-21].

T300 Bobcat Loader


20-45-8 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-26
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Actuator Removal And Installation (Out of Loader)


(Cont’d)

Figure 20-45-24

1
1

P-54343

Using a drift pin and a hammer, remove the actuator


linkage pin (Item 1) [Figure 20-45-26] from the actuator
and the tilt spool.
1
P-54341 Remove the actuator and linkage pin from the valve.

Figure 20-45-27
Remove the two mount bolts (Item 1) [Figure 20-45-24]
from the lift actuator.

Installation: Tighten the mounting bolts to 90-100 in.-lb.


(10,2-11,3 N•m) torque.

Figure 20-45-25
1

P-54340

Inspect the O-ring (Item 1) [Figure 20-45-27] on the face


of the actuator, and replace as needed.
1
Check the linkage pin (Item 2) [Figure 20-45-27] and
P-54342 replace as needed.

Slide the actuator mount bracket (Item 1) [Figure 20-45-


25] away from the control valve.

Pull the actuator away from the control valve [Figure 20-
45-25].

T300 Bobcat Loader


20-45-9 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Actuator Removal And Installation (Out of Loader)


(Cont’d)

Figure 20-45-28

1 2

3
P-51738

NOTE: The two longer bolts (Item 1) are used to


mount the lift actuator and end cap (Item 2)
[Figure 20-45-28] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-45-28].

Installation: Tighten the mounting bolts to 90-100 in.-lb.


(10,2-11,3 N•m) torque (Item 1) [Figure 20-45-28]

T300 Bobcat Loader


20-45-10 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Identification Chart

Figure 20-45-29

J2
C2 J4 C3
D5 B3 E3
E3
G1 G2

D3
B2 A3
D4 E2
F2
A2

D1 A1
E1 D2
H2 B1
F1 H3
MR C1
H1
J3
J1
MS1972

ITEM T300 LOADER ITEM T300 LOADER


A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 LIft Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Load Check/BICS™ Valve G2 Auxiliary Solenoid Stem
Lift H1 BICS™ Valve Solenoid
C2 Load Check Valve Tilt Function
H2 BICS™ Lock Valve (Tilt)
C3 Load Check Valve Auxiliary Function
D1 Anti-Cavitation Valve H3 BICS™ Lock Valve (Lift)
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief/Anti-Cavitation Valve – 4000 PSI J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End) J3 Lift Arm By-Pass Orifice
D3 Port Relief/Anti-Cavitation Valve – 4000 PSI J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 3300 PSI
D4 Port Relief/Anti-Cavitation Valve – 4000 PSI
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

T300 Bobcat Loader


20-45-11 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-32
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

BICS™ Valve, Lift Load Check Valve Removal And


Installation
1
Figure 20-45-30

3
1
P-54292

Remove and install new O-rings (Item 1) and back-up


ring (Item 2) [Figure 20-45-32].

Check the load check valve (Item 3) [Figure 20-45-32].


P-54344

Remove the charge tubeline (Item 1) [Figure 20-45-30]


from the BICS valve fitting on the top of the lift load check
valve.

Figure 20-45-31

P-54355

Remove the lift load check valve (Item 1) [Figure 20-45-


31] and fitting from the the top of the control valve.

Installation: Lubricate the O-ring and threads and


tighten to 55-65 ft.-lb. (75-88 N•m) torque.

T300 Bobcat Loader


20-45-12 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Anti-Cavitation Valve (Lift, Rod End)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D) Figure 20-45-35
Load Check Valve Removal And Installation (Tilt &
Auxiliary)

Figure 20-45-33

2 1

1
P-51742

At the back side of the control valve, remove the lift


section anti-cavitation valve (Item 1) [Figure 20-45-35].
P-54345

At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-45-33]. WARNING
At the front side of the control valve locate the auxiliary When repairing hydrostatic and hydraulic systems,
section load check valve (Item 2) [Figure 20-45-33]. clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
NOTE: The tilt and auxiliary load check valves are tubelines and ports to keep dirt out. Dirt can quickly
interchangeable. damage the system.
I-2003-0888
Figure 20-45-34

Figure 20-45-36
4

1
3
2

P-51453
1

Remove the spring (Item 1) and poppet (Item 2) [Figure


20-45-34]. P-51452

Check the orifice (Item 3) [Figure 20-45-34] in the


poppet to be sure it is not plugged. Always use new O-ring (Item 1) [Figure 20-45-36] on the
anti-cavitation valve plug.
Installation: Install a new O-ring (Item 4) [Figure 20-45-
34] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lb. (52-61 N•m)
torque.
T300 Bobcat Loader
20-45-13 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Lift, Base End)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D) Figure 20-45-38
Anti-Cavitation Valve (Lift, Rod End) (Cont’d)

Figure 20-45-37

1 1
3
2
P-51742

Loosen the lift circuit port relief/anti cavitation valve (Item


P-51453 1) [Figure 20-45-38].

Figure 20-45-39
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-45-37].

Check the orifice (Item 3) [Figure 20-45-37] in the


poppet to be sure it is not plugged.

Installation: Install a new O-ring (Item 4) [Figure 20-45-


37] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lb. (52-61 N•m)
torque.

P-51451

Replace the O-ring (Item 1) [Figure 20-45-39] before


installation.

Installation: Lightly lubricate with oil and tighten to 38-45


ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-45-14 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D) Figure 20-45-42
Port Relief/Anti-Cavitation Valve (Tilt, Base End)

Figure 20-45-40

P-51742

Remove the tilt port relief/anti cavitation valve (Item 1)


P-51742 [Figure 20-45-42] from the rod end of the tilt section.

Figure 20-45-43
Remove the tilt port relief/anti cavitation valve (Item 1)
[Figure 20-45-40] from the base end of the tilt section.

Figure 20-45-41

1 P-51455

Replace the O-ring (Item 1) [Figure 20-45-43] before


P-51454 installation.

Installation: Lightly lubricate with oil and tighten to 38-45


Replace the O-ring (Item 1) [Figure 20-45-41] before ft.-lb. (52-61 N•m) torque.
installation.

Installation: Lightly lubricate with oil and tighten to 38-45


ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-45-15 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-46
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Port Relief Valve 1

Figure 20-45-44

P-51743

The control valve may be equipped with an optional


auxiliary port relief valve (Item 1) [Figure 20-45-46].

P-51742 Remove the auxiliary port relief valve.

Figure 20-45-47
Remove the port relief plug (Item 1) [Figure 20-45-44]
from the auxiliary circuit of the control valve.

Figure 20-45-45

P-51640

1
Installation: Always use new O-rings (Item 1) [Figure
P-51801 20-45-47]. Lightly lubricate with oil and tighten to 38-45
ft.-lb. (52-61 N•m) torque.
Installation: Always use new O-rings (Item 1) [Figure
20-45-45]. Lightly lubricate with oil and tighten to 38-45
ft.-lb. (52-61 N•m) torque.

T300 Bobcat Loader


20-45-16 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-45-50
(SELECTABLE JOYSTICK CONTROL) (SJC)
(CONT’D)

Plug Removal

Figure 20-45-48

1
P-51461

At the bottom side of the control valve remove the plug


(Item 1) [Figure 20-45-50].

P-51459 Figure 20-45-51

At the top side of the control valve, remove the plug (Item
1) [Figure 20-45-48].

Figure 20-45-49

P-51462

Installation: Always use new O-rings (Item 1) [Figure


20-45-51]. Tighten to 60 ft.-lb. (81,3 N•m) torque.
1
P-51460

Installation: Always use new O-rings (Item 1) [Figure